Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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INSULATING DEVICE
Cross Reference to Related Application
[01] This application claims priority to U.S. Provisional Patent
Application No. 62/517,490, filed
June 9, 2017, which is expressly incorporated herein by reference in its
entirety for any and
all non-limiting purposes.
Field
[02] The present disclosure relates generally to non-rigid, portable,
insulated devices or
containers useful for keeping food and beverages cool or warm, and, more
particularly, an
insulating device with a waterproof closure.
Background
[03] Coolers are designed to keep food and beverages at lower temperatures.
Containers may be
composed of rigid materials such as metal or plastics or flexible materials
such as fabric or
foams. Coolers can be designed to promote portability. For example, rigid
containers can
be designed to incorporate wheels that facilitate ease of transport or coolers
can be
designed in smaller shapes to allow individuals to carry the entire device.
Non-rigid
containers can be provided with straps and/or handles and may in certain
instances be made
of lighter weight materials to facilitate mobility. Non-rigid coolers that
maximize portability
can be designed with an aperture on the top that allows access to the interior
contents of
the cooler. The aperture can also be provided with a closure.
Summary
[04] This Summary provides an introduction to some general concepts
relating to this invention
in a simplified form that are further described below in the Detailed
Description. This
Summary is not intended to identify key features or essential features of the
invention.
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[05] Aspects of the disclosure herein may relate to insulating devices
having one or more of (1) a
waterproof closure (2) an outer shell, (3) an inner liner, (4) an insulating
layer floating freely
in between the outer shell and the inner liner, (5) a waterproof storage
compartment, or (6)
a lid assembly, which can include at least a portion of the insulating layer
that extends below
a closure adapted to close the opening.
Brief Description of the Drawings
[06] The foregoing Summary, as well as the following Detailed Description,
will be better
understood when considered in conjunction with the accompanying drawings in
which like
reference numerals refer to the same or similar elements in all of the various
views in which
that reference number appears.
[07] Fig. 1A shows a left front perspective view of an example insulating
device in accordance
with an aspect of the disclosure;
[08] Fig. 16 shows a frontside perspective view of the example insulating
device of Fig. 1A
without the shoulder strap;
[09] Fig. 2 shows a backside perspective view of the example insulating
device of Fig. 1A without
the shoulder strap;
[10] Fig. 3A shows a top perspective view of the example insulating device
of Fig. 1A without the
shoulder strap;
[11] Fig. 36 shows a top view of a portion of the example insulating device
of Fig. 1A;
[12] Fig. 3C shows a portion of an alternate top perspective view of the
example insulating device
of Fig. 1A;
[13] Fig. 4 shows a bottom perspective view of the example insulating
device of Fig. 1A;
[14] Fig. 5A illustrates a schematic of a cross-sectional view of the
example insulating device of
Fig. 1A;
[15] Fig. 56 illustrates another schematic of an enlarged portion of a
cross-sectional view of the
example insulating device of Fig. 1A;
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[16] Fig. 6 illustrates an exemplary process flow diagram for forming an
insulating device;
[17] Figs. 7A-7J illustrate exemplary methods of forming an insulating
device;
[18] Figs. 8A and 88 depict perspective views of an alternative example
insulating device.
[19] Fig. 9 depicts a portion of an exemplary closure and an example test
method for determining
if an insulating device maintains the contents therein.
[20] Fig. 10 depicts an example test for determining the strength of an
insulating device.
[21] Fig. 11 shows a front view of another exemplary insulating device.
[22] Fig. 12 shows a side view of the exemplary insulating device of Fig.
11.
[23] Fig. 13 shows a front perspective view of the exemplary insulating
device in an alternate
configuration.
[24] Fig. 14A shows a side and cross-sectional view of the exemplary
insulating device of Fig. 11.
[25] Fig. 1413 shows an enlarged section of Fig. 14A.
[26] Fig. 15 shows a schematic exploded view of an exemplary insulation
layer for the example
insulating device of Fig. 11.
[27] Fig. 16A shows a portion of another example insulating device.
[28] Fig. 1613 shows a side view of the example insulating device of Fig.
16A.
[29] Fig. 17 shows a perspective view of another example insulating device.
[30] Fig. 18 shows a front view of the insulating device of Fig. 17.
[31] Fig. 19 shows a rear view of the insulating device of Fig. 17
[32] Fig. 20 shows a side view of the insulating device of Fig. 17.
[33] Fig. 21 shows a cross-sectional view of the insulating device of Fig.
17.
[34] Fig. 22 shows a schematic exploded view of an exemplary insulation
layer for the example
insulating device of Fig. 17.
[35] Fig. 22A shows a front view of an exemplary insulation layer for the
example insulating
device of Fig. 17.
[36] Fig. 23 illustrates an exemplary testing method.
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[01] Fig. 24 shows a front view of an example insulating device in
accordance with an aspect of
the disclosure;
[02] Fig. 25 shows a side view of the example insulating device of Fig. 24.
[03] Fig. 26 shows a rear view of the example insulating device of Fig. 24.
[04] Fig. 27 shows a top view of the example insulating device of Fig. 24.
[05] Fig. 28 shows a bottom view of the example insulating device of Fig.
24.
[06] Fig. 29A shows a cross-sectional view of the example insulating device
of Fig. 24.
[07] Fig. 298 shows a portion of a cross-sectional view of the example
insulating device of Fig.
24.
[08] Fig. 30 shows an isometric view of an exemplary insulation layer of
the example insulating
device of Fig. 24.
[09] Fig. 31 shows an alternative embodiment for an inner liner of an
insulating device.
[10] Fig. 32 shows the insulating device of Fig. 24 in the opened position.
[11] Fig. 32A shows an example manufacturing method for forming an
insulating device.
[12] Fig. 33 shows an example method of securing a handle to an insulating
device.
[13] Fig. 34 illustrates an exemplary testing method.
[14] Fig. 35A shows a front view of another exemplary insulating device.
[15] Fig. 358 shows a side view of the exemplary insulating device of Fig.
35A.
[16] Fig. 35C shows a rear view of the exemplary insulating device of Fig.
35A.
[17] Fig. 35D shows a top view of the exemplary insulating device of Fig.
35A.
[18] Fig. 35E shows a bottom view of the exemplary insulating device of
Fig. 35A.
[19] Fig. 35F shows a cross-sectional view of the exemplary insulating
device of 35A.
[20] Fig. 36A shows a partial cross-sectional view of an exemplary lid.
[21] Fig. 368 shows a transparent top view of the exemplary lid of Fig.
36A.
[22] Fig. 37 shows a front view an alternate embodiment of the insulating
device of 35A.
[23] Fig. 38 shows a side view an alternate embodiment of the insulating
device of 35A.
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[24] Fig. 39 shows an exploded view of the side view of the insulating
device of FIG. 37.
[25] Fig. 40A shows an alternate cross-sectional view of the exemplary
insulating device of 35A.
[26] Fig. 4013 shows the insulating device of Fig. 40A in an alternate
opened configuration.
[27] Fig. 41A shows an alternate cross-sectional view of the exemplary
insulating device of 35A.
[28] Fig. 416 shows the insulating device of Fig. 41A in an opened
configuration.
[29] FIG. 42 schematically depicts an aerogel insulating structure,
according to one or more
aspects described herein.
[30] FIG. 43 schematically depicts one implementation of the aerogel
insulating structure,
according to one or more aspects described herein.
[31] FIG. 44 schematically depicts one implementation of the aerogel,
according to one or more
aspects described herein.
[32] FIG. 45 schematically depicts another implementation of the aerogel,
according to one or
more aspects described herein.
[33] FIG. 46 schematically depicts another implementation of the aerogel,
according to one or
more aspects described herein.
[34] FIG. 47 schematically depicts another implementation of the aerogel,
according to one or
more aspects described herein.
[35] FIG. 48 schematically depicts another implementation of the aerogel
insulating structure,
according to one or more aspects described herein.
[36] FIG. 49 schematically depicts another implementation of the aerogel
insulating structure,
according to one or more aspects described herein.
[37] FIG. 50 schematically depicts another implementation of the aerogel
insulating structure,
according to one or more aspects described herein.
[38] FIG. 51 schematically depicts another implementation of an aerogel
insulating structure,
according to one or more aspects described herein.
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[39] FIG. 52 depicts another implementation of an insulating device,
according to one or more
aspects described herein.
[40] FIG. 53 schematically depicts a cross-sectional view of the insulating
device along line 53-53
schematically depicted in FIG. 52.
[41] FIG. 54 schematically depicts a cross-sectional view of an alternative
implementation of an
insulating device and lid assembly, according to one or more aspects described
herein.
[42] FIG. 55 schematically depicts another cross-sectional view of an
alternative implementation
of an insulating device and lid assembly, according to one or more aspects
described herein.
[43] FIG. 56 schematically depicts a cross-sectional view of an insulating
device and lid assembly,
according to one or more aspects described herein.
[44] FIG. 57 schematically depicts a cross-sectional view of an insulating
device, according to one
or more aspects described herein.
[45] FIG. 58 schematically depicts a cross-sectional view of an insulating
device, according to one
or more aspects described herein.
[46] FIG. 59 schematically depicts an isometric view of an insulating
container and lid structure,
according to one or more aspects described herein.
[47] FIG. 60 schematically depicts an exploded isometric view of the
insulating container,
according to one or more aspects described herein.
[48] FIG. 61 schematically depicts a cross-sectional view of an insulating
device, according to one
or more aspects described herein.
[49] FIG. 62 depicts a cross-sectional view of a lid structure, according
to one or more aspects
described herein.
[50] FIG. 63 depicts a deformable insulator, according to one or more
aspects described herein.
[51] FIG. 64 depicts an insulating container, according to one or more
aspects described herein.
[52] FIG. 65 schematically depicts a cross-sectional view of another
implementation of an
insulating container, according to one or more aspects described herein.
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Detailed Description
[53] In the following description of the various examples and components of
this disclosure,
reference is made to the accompanying drawings, which form a part hereof, and
in which
are shown by way of illustration various example structures and environments
in which
aspects of the disclosure may be practiced. It is to be understood that other
structures and
environments may be utilized and that structural and functional modifications
may be made
from the specifically described structures and methods without departing from
the scope of
the present disclosure.
[54] Also, while the terms "frontside," "backside," "top," "base,"
"bottom," "side," "forward,"
and "rearward" and the like may be used in this specification to describe
various example
features and elements, these terms are used herein as a matter of convenience,
e.g., based
on the example orientations shown in the figures and/or the orientations in
typical use.
Nothing in this specification should be construed as requiring a specific
three dimensional or
spatial orientation of structures in order to fall within the scope of the
claims.
[55] FIGS. 1-4 depict an exemplary insulating device 10 that can be
configured to keep desired
contents stored cool or warm for an extended period of time. The insulating
device can
generally include an outer shell 501, a closure 301, an insulating layer 502,
and an inner liner
500. As shown in Fig. 3C, the inner liner 500 forms a chamber or receptacle
504 for receiving
the desired contents therein. As shown in Fig. 1A, various handles, straps,
and webs (e.g.
210, 212, 218, 224) can also be included on the insulating device 10 for
carrying, holding, or
securing the insulating device 10.
[56] The insulating device 10 can be configured to keep desired contents
stored in the receptacle
504 cool or warm for an extended period of time. In one example, the
insulating device 10
can also be designed to maintain water inside the inner chamber or receptacle
504, and the
insulating device 10 can be configured to be water "resistant" from the
outside in. In other
words, the insulating device 10 can be formed "water tight" inside the inner
liner 500, and
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water cannot leak into the inner liner 500 from the outside or out from the
inside of the
inner liner 500 when the closure 301 is in the closed position.
[57] Fig. 4 depicts a bottom view of the insulating device 10. As shown in
Fig. 4, the insulating
device 10 may include a base 215 and a base support ridge 400. The base
support ridge 400
can provide structural integrity and support to the insulating device 10 when
the insulating
device 10 is placed onto a surface.
[58] In one example, as shown in Figs. 3A and 4, the top of the outer shell
501 has a first
perimeter circumference (Tar) and the bottom of the outer shell 501 has a
second perimeter
circumference or a base perimeter 401 (BA. The circumference of the top of the
outer shell
501 can be equal to the circumference on the bottom when folded into a
cylinder, and Bar
can be equal to Tar. In one example, the first circumference and the second
circumference
can both have an oval shape to form an elongated or elliptical cylinder. In
one example, the
top outer layer 501a can have a length of 23.5 inches and a width of 5.5
inches. Therefore,
the length to width ratio of the top outer layer 501a can be approximately
4.3. Additionally,
the base 215 can have a length of 20.0 inches and a width of 12.25 inches.
Therefore, the
length to width ratio of the base 215 is approximately 1.6. In this example,
the length to
width ratio of the upper wall can be greater than the length to width ratio of
the base.
[59] In one example, as shown in Fig. 5A, the inner layer or inner liner
500 can be formed of a top
inner liner portion or first inner liner portion 500a, an inner layer mid
portion or second
portion 500b, and an inner layer bottom portion 500c. The top inner liner
portion 500a, the
inner layer mid portion 500b, and the inner layer bottom portion 500c are
secured together,
by for example welding, to form the chamber 504. The chamber 504 can be a "dry
bag," or
vessel for storing contents. In one example, after the top inner liner portion
500a, the inner
layer mid portion 500b, and the inner layer bottom portion 500c are secured or
joined
together, a tape, such as a TPU tape can be placed over the seams joining the
sections of the
chamber 504. The inner liner 500 can, thus, either maintain liquid in the
chamber 504 of the
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insulating device 10 or prevent liquid contents from entering into the chamber
504 of the
insulating device 10. In one example, as will be described in further detail
below, the inner
liner 500 can be suspended in the insulating device 10 by only the closure
301.
[60] The insulating layer 502 can be located between the inner liner 500
and the outer shell 501,
and can be formed as an insulator to assist in maintaining the internal
temperature of the
receptacle 504. In one example, the insulating layer 502 can be a free
floating layer that is
not attached directly to the outer shell 501 or the inner liner 500. The
insulating layer 502
can be formed of a first portion 502a and a second portion or base portion
502b. The first
portion 502a and the second portion 502b can be formed of an insulating foam
material as
will be described in further detail below.
[61] The first portion 502a can have a rectangular shape that maintains its
form when folded into
a cylinder and placed in between the inner liner 500 and the outer shell 501
and when
encased from above by the outer shell 501. The insulating layer 502 maintains
its shape
which results in the basic oval-cylindrical shape of the insulating device 10.
Therefore,
similar to the outer shell 501, the top of the insulating layer 502 has a
first perimeter
circumference, and the bottom of the insulating layer 502 has a second
perimeter
circumference. The first perimeter circumference of the insulating layer 502
can be equal to
the second perimeter circumference of the insulating layer 502.
[62] The base portion 502b can be included to provide additional insulation
along the insulating
device 10 at base 215. The base portion 502b can be formed as an oval shape to
close off a
lower opening 506 formed by the cylindrical shape of the insulating layer 502.
[63] Additionally, the bottom portion of the insulating device 10 can
include an additional base
support layer 505, which adds to the insulation and the structural integrity
of the insulating
device 10. The base support layer 505 may also provide additional protection
around the
bottom of the insulating device 10. In one example, the base support layer 505
can be
formed from EVA foam. The base support layer 505 may include a certain design
such as a
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logo or name that can be molded or embossed directly into the material. The
base support
ridge 400, which provides structural integrity and support to the insulating
device 10 can
also be molded or embossed directly into the base support layer 505. In one
example, the
base support layer 505 and the base portion 502b can be detached for ease of
assembly.
[64] The outer shell 501 can be formed of a top outer layer portion or
first shell portion 501a, an
outer layer or second outer shell portion 501b, and a bottom or third shell
portion 501c.
The outer shell 501 provides a covering for the insulating device 10. In one
example, the
insulating layer 502 can be suspended freely within the outer shell 501.
However, it is
contemplated that any of the layers could be secured or formed as a one-piece
integral
structure. The outer shell 501 can be configured to support one or more
optional handles or
straps (e.g. 210, 212, 218). In this regard, the outer shell 501 can also
include multiple
reinforcement areas or patches 220 that are configured to assist in
structurally supporting
the optional handles or straps (e.g. 210, 212, 218). The handles or straps
(e.g. 210, 212, 218)
and other attachments can be stitched using threads 222, however these threads
222 do
not, in one example, extend through the outer shell 501 into the insulating
layer 502.
Rather, the threads are sewn to the patches 220, and the patches 220 can be RE
welded to
the outer shell 501 or by any other method disclosed herein.
[65] As shown in Fig. 5A, the first outer shell portion 501a may be
attached to the second shell
portion 501b by stitching 510. However, the first outer shell portion 501a can
be attached
to the second shell portion 501b using any known method, e.g., polymer
welding, stitching,
or other adhesive around the entire perimeter of the second shell portion
501b.
[66] Additionally, in one example, the base support layer 505, which can be
formed from EVA
foam, can be secured to bottom or third shell portion 501c by lamination. The
second shell
portion 501b can be secured to the third shell portion 501c and the base
support layer 505
by polymer welding (e.g. RE welding), stitching, or adhesives.
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[67] The insulating device 10 can include two carry handles 210 that are
connected to the
frontside 216 of the insulating device 10 and the backside 217 of the
insulating device 10. In
one particular example, a shoulder strap 218 can be attached via plastic or
metal clip to the
ring 214 attached to side handles 212 to facilitate carrying insulating device
10 over the
shoulder. The insulating device 10 may also include side handles 212 on each
end of the
cooler. The side handles 212 provide the user with another option for grasping
and carrying
the insulating device.
[68] Carry handles 210 may also form a slot for receiving rings 214 near
the bottom of the
attachment point of the carry handles to the insulating device 10. The rings
214 can be
secured to the carry handles 210 and the attachment points 213 by stitching,
adhesive, or
polymer welding and can be used to help secure or tie down the insulating
device 10 to
another structure such as a vehicle, vessel, camping equipment, and the like
or various
objects such as keys, water bottle bottles, additional straps, bottle openers,
tools, other
personal items, and the like.
[69] Additionally, as shown in Fig. 2, webbing formed as loops 224 can be
sewn onto the straps
forming the handles 210 on the back of the insulating device 10. The loops 224
can be used
to attach items (e.g., carabineers, dry bags) to the insulating device 10. The
side handles 212
can also provide the user with another option for securing the insulating
device 10 to a
structure.
[70] In one example, the carry handles 210, side handles 212, shoulder
strap 218 and attachment
points 213 can be constructed of nylon webbing. Other materials may include
polypropylene, neoprene, polyester, Dyneema, Kevlar, cotton fabric, leather,
plastics,
rubber, or rope. The carry handles 210 and side handles 212 can be attached to
the outer
shell by stitching, adhesive, or polymer welding.
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[71] The shoulder strap 218 can be attached to the insulating device 10 at
attachment points
213. The attachment points 213 can be straps that also form a slot for
receiving rings 214.
The rings 214 can provide for the attachment of the shoulder strap 218.
[72] In one example, the rings 214 can be Acetal D-rings. Rings 214 in can
be plastic, metal,
ceramic, glass, alloy, polypropylene, neoprene, polyester, Dyneema, and
Kevlar, cotton
fabric, leather, plastics, rubber, or rope. Rings 214 can include other
shapes, sizes, and
configurations other than a "D" shape. Examples include round, square,
rectangular,
triangular, or rings with multiple attachment points. Additionally, pockets or
other storage
spaces can be attached to the outside of the insulating device 10 in addition
to the carry
handles 210 and side handles 212.
[73] In one example, the closure 301 can be substantially waterproof or a
barrier to prevent
liquid contents from either entering or exiting the insulating device.
Additionally, the
closure 301 can be impervious to liquid such that insulating device 10 liquid
penetration is
prevented at any orientation of the insulating device 10. Also maintaining the
closure 301 in
flat plane can assist in providing a water tight seal.
[74] Figs. 3A-3C depicts top views of the insulating device 10, and depicts
the top outer layer or
the first outer shell portion 501a and the closure 301. The top outer layer
501a depicted in
Fig. 3A can be secured to the closure 301. In one example, the closure 301 can
be a
waterproof zipper assembly and can be watertight up to 7 psi above atmospheric
pressure
during testing with compressed air. However, in other examples, the water
tightness of the
closure 301 can be from 5 psi to 9 psi above atmospheric pressure and in other
examples,
the water tightness of the closure 301 can be from 2 psi to 14 psi above
atmospheric
pressure. The waterproof zipper assembly can include a slider body 303 and
pull-tab 302.
Fig. 38 shows a magnified view of the closure 301 that includes bottom stop
304 and teeth
or a chain 305. In one particular example, the waterproof zipper assembly can
be
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constructed with plastic or other non-metallic teeth 305 to prevent injury
when retrieving
food or beverages from the inner chamber 504.
[75] As shown in Fig. 3C, the closure 301 is open or unzipped and an
aperture 512 formed in the
outer shell 501 and the inner liner 500 is open and reveals the inner liner
500 and the inner
chamber 504. It is contemplated that the closure or seal 301 can include
various sealing
devices in addition to the depicted waterproof zipper assembly in Figs. 3A-3C.
For example,
Velcro, snaps, buckles, zippers, excess material that is folded multiple times
to form a seal
such as a roll-down seal, seals, metal or plastic clamps and combinations
thereof could be
used to seal the inner liner 500 and the outer shell 501.
[76] Figs. 8A and 8B depict another exemplary insulating device 1010, which
has similar features
and functions as the example discussed above in relation to Figs. 1A-5I3 in
which like
reference numerals refer to the same or similar elements. However, in this
example, a loop
patch 1015 can be provided on the front of the bag. The loop patch 1015 can be
configured
to receive many types of items or a corresponding group of hooks, which can be
placed onto
the surface anywhere on various items, such as fishing lures, keys, bottle
openers, card
holders, tools, other personal items, and the like. The loop patch 1015 can
include a logo,
company name, personalization, or other customization. The loop patch 1015 can
be
formed of by needle loops and can have a high cycle life of over 10,000
closures. In addition,
the loop patch can be washable and UV resistant to prevent discoloration. The
loop patch
can be selected based on a desired sheer and peel strength depending on the
types of
materials that are to be secured to the insulating device 1010.
[77] In the example shown in Figs. 8A and 8B, additionally, a strip 1013 of
material can be
provided along the bottom of the bag, which can provide additional strength
and
reinforcement to the outer shell 1501, and may enhance the aesthesis of the
insulating
device 1010.
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[78] Example methods of forming the insulating device 10 will now be
described. A general
overview of an exemplary assembly process of the insulating device 10 is
depicted
schematically in FIG. 6. The various steps, however, need not necessarily be
performed in
the order described. As shown in step 602 first the portions used to form the
inner liner
500, the outer shell 501, and the insulating layer 502 can be formed or cut to
size. In step
604, a top cap assembly 300 can be assembled to the closure 301. In step 606,
the inner
liner 500 can be formed, and in step 608, the top cap assembly 300 can be
welded to the
inner liner 500. In step 610, the outer shell 501 can be formed. In step 612,
the insulation
layer 502 can be assembled, and in step 616, the insulation layer 502 can be
placed into the
inner liner. Finally, in step 618, the top cap assembly 300 can be secured to
the outer shell
501.
[79] Referring to step 602, as shown in Fig. 7A and 7B, inner liner top
portions or first inner liner
portions 500a and top outer layer 501a that form the top cap assembly 300 can
be formed
or cut to size. Fig. 7C shows a second portion or base portion 502b of the
insulating layer
502 being cut or formed to size from stock foam. In this example, the base
portion 502b is
cut from the stock foam 530, by cutting tool 700. In one example, the cutting
tool 700 can
be formed in the shape of the base portion 502b.
[80] Referring now to step 604 and Fig. 7D, the top outer layer 501a and
the top inner liner
portion 500a can be secured to the closure 301 to form the top cap assembly
300, and the
top outer layer 501a and the top inner liner portion 500a can be secured to
the closure 301
in a flat, horizontal plane. Referring to Figs. 5A-56 the top outer layer 501a
can be attached
by polymer welding or adhesive to closure 301. In particular as shown
schematically in Fig.
5B, the closure 301 can be provided with a first flange 301a and a second
flange 301b, which
can form waterproof zipper tape 306. The top outer layer 501a can be attached
directly to
the top surfaces of the first flange 301a and the second flange 301b of the
closure 301. In
one example, the first flange 301a and the second flange 301b, can be RF
welded to the
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underside of the top outer layer 501a. In another example, as shown in Fig.
7E, the top
inner liner portion 500a can be provided with tabs 515. Tabs 515 can assist in
the assembly
process to keep the outer strips of the top inner liner portion 500a in place
during assembly
and can be removed after the top cap assembly 300 is formed.
[81] In one example, the top inner liner portion 500a can be attached to
the structure of the
insulating device 10 as shown schematically in Fig. 5B. In particular, the top
inner liner
portion 500a can be attached to the bottom of the closure 301. For example, as
shown in
Fig. 5B, and a first end 540a and a second end 540b of the top inner liner
portion 500a can
be attached to undersides of the first flange 301a and the second flange 301b.
The top inner
liner portion 500a and the top outer layer 501a can be attached to the closure
301 by
polymer welding or adhesive. Polymer welding includes both external and
internal methods.
External or thermal methods can include hot gas welding, hot wedge welding,
hot plate
welding, infrared welding and laser welding. Internal methods may include
mechanical and
electromagnetical welds. Mechanical methods may include spine welding, stir
welding,
vibration welding, and ultrasonic welding.
Electromagnetical methods may include
resistance, implant, electrofusion welding, induction welding, dielectric
welding, RF (Radio
Frequency) welding, and microwave welding. The welding can be conducted in a
flat or
horizontal plane to maximize the effectiveness of the polymer welding to the
construction
materials. As a result, a rugged watertight seam can be created that prevents
water or fluids
from escaping from or into the inner chamber 504.
[82] In a particular example, the polymer welding technique to connect the
top inner liner
portion 500a to the bottom of the closure 301 can include RF welding. The RF
welding
technique provides a waterproof seam that prevents water or any other fluid
from
penetrating the seam at pressure up to 7 psi above atmospheric pressure. The
insulating
device 10, therefore, can be inverted or submerged in water and leakage is
prevented both
into and out of the internal chamber 504 formed by inner liner 500. In one
example, the
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insulating device 10 can be submerged under water to a depth of about 16 feet
before water
leakage occurs. However, it is contemplated that this depth could range from
about 11 feet
to 21 feet or 5 feet to 32 feet before any leakage occurs.
[83] Next referring to step 606 and Fig. 7F, the inner layer mid-portion
500b can be formed by RF
welding. As shown in Fig. 7F, the inner layer mid-portion 500b can be formed
of a
rectangular sheet of material. The inner layer mid-portion 500b can also be
secured to the
inner layer bottom portion 500c in a subsequent step not shown.
[84] Referring to step 608 and Figs. 7G and 7H, the inner layer mid portion
500b and the inner
layer bottom portion 500c can be secured to the top cap assembly 300 using an
RF welding
operation.
[85] Referring to step 610, the second shell portion 501b and the third
shell portion 501c, which
supports the base support layer 505, can be RF welded to construct the outer
shell 501 for
the insulating device 10. In one example, as shown schematically in Fig. 5A,
the top outer
layer 501a can be sewed to the perimeter of the second shell portion 501b to
form the outer
shell 501 of the insulating device. A fabric binding can be used to cover the
stitched seam
edges of the second shell portion 501b and the top outer layer 501a. This
assists in closing
or joining the outer shell 501 around the insulating layer 502.
[86] Referring to step 612 and Fig. 71, the insulating layer 502 can be
constructed. In one example
the first portion 502a of the insulating layer 502 can be formed into a
rectangular shape and
can be secured at the smaller sides of the rectangular shape using double
sided tape to form
the cylindrical shape. The second portion or base portion 502b can be formed
into an oval
shape that can have a smaller circumference than the circumference of the
cylindrical shape
of the first portion 502a. The second portion 502b can be secured to the first
portion 502a
also using a double-sided tape to form the insulating layer 502. In one
example, double
sided tape can be placed either around the inner perimeter of the first
portion 502a cylinder
or around the outer perimeter of the base portion 502b, and the base portion
502b can be
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adhered to the first portion 502a. Other methods of securing the base portion
502b to the
first portion 502a to form the insulating layer 502 are contemplated, such
adhesives or
polymer welding.
[87] Referring to step 614, the assembled insulating layer 502 can be
placed into the outer shell
501. In step 616, the formed inner liner 500 and top cap assembly 300 can be
placed into
the insulating layer 502.
[88] Finally in step 618 the top cap assembly 300 can be sewed to the outer
shell 501 to form
seams 520 as depicted schematically in Fig. 5A. In this way, neither the inner
liner 500 nor
the outer shell 501 need to be bound to the insulating layer 502. Also the
inner liner 500 is
only connected to the closure 301 and the closure 301 holds the inner liner
and the outer
shell 501 together, which results in a simpler manufacturing process. After
sewing the top
cap assembly 300 to the outer shell 501, a fabric binding is added to cover
the raw edges
adjacent the seams 520. Thus, the top seams 520 can be the only primary seams
on the
insulating device 10 that are created by stitching.
[89] In one particular example, the inner liner 500 and the outer shell 501
can be constructed
from double laminated TPU nylon fabric. Nylon fabric can be used as a base
material for the
inner liner 500 and the outer shell 501 and can be coated with a TPU laminate
on each side
of the fabric. The TPU nylon fabric used in one particular example is 0.6
millimeters thick, is
waterproof, and has an antimicrobial additive that meets all Food and Drug
Administration
requirements. However, it is contemplated that the fabrics used to construct
the insulating
device incorporate antimicrobial materials to create a mildew-free environment
that is food
contact surface safe. In one specific example, the nylon can be 840d nylon
with TPU.
Alternative materials used to manufacture the inner shell or chamber 504 and
outer shell
501 include PVC, TPU coated nylon, coated fabrics, and other weldable and
waterproof
fabrics.
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[90] A closed cell foam can be used to form the insulating layer 502 that
is situated in between
the inner liner 500 and the outer shell 501. In one example, the insulating
layer 502 is 1.0
inches thick. In one example, the insulating layer 502 can be formed of
NIBR/PVC blend or
any other suitable blend. The thermal conductivity of an example insulating
layer 502 can
be in the range of 0.16¨ 0.32 13TU.in/(hrscift. F), and the density of the
insulating layer 502
can be in the range of 0.9 to 5 lbs/ft3. In one example, the thermal
conductivity of the
insulating layer 502 can be in the range of 0.25 13TU.in/(hrscift. F), and the
density of the
insulating layer 502 can be 3.5 lbs/ft3.
[91] The foam base can be manufactured from an NIBR/PVC blend or any other
suitable blend. In
addition to the base portion 502b of the insulating layer 502, the insulating
device 10 may
also include an outer base support layer 505 constructed of foam, plastic,
metal or other
material. In one example, the base portion 502b can be detached from the base
support
layer. In one example, the base portion 502b is 1.5 inches thick. Additionally
as shown in
Fig. 5A, the EVA foam base support layer 505 can be 0.2 inches thick. Although
the base
support layer 505 is laminated to the base outer layer or third shell portion
501c, in an
alternative example, the base support layer 505 can be attached to the bottom
of the base
portion 502b by co-molding, polymer welding, adhesive, or any known methods.
[92] A heat gain test was conducted on the exemplary insulating device 10.
The purpose of a
heat gain test is to determine how long the insulating device can keep
temperature below
50 F at an ambient of 106 F 4 with the amount of ice based on its internal
capacity.
[93] The procedure is as follows:
[94] 1. Turn on the oven and set to 106 F 4. Allow the oven to stabilize
for at least one hour.
[95] 2. Turn on the chart recorder. The recorder shall have three J-
thermocouples connected to
it to chart the following temperatures: (1) Test unit, (2) Oven, and (3) Room
ambient.
[96] 3. Stabilize the test unit by filling it to half its capacity with ice
water, and allowing it to sit for
minutes at room temperature (72 F 2).
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[97] 4. After 5 minutes, pour out the contents, and immediately connect the
J-thermocouple end
to the inside bottom center of the unit. The thermocouple wire end must be
flush to the
inside bottom surface and secured with an adhesive masking tape.
[98] 5. Pour the correct amount of ice ensuring the thermocouple wire is
not moved. Amount of
ice is based on 4 lbs. per cubic feet of the internal capacity of the unit.
[99] 6. Close the lid and position the test unit inside the oven.
[100] 7. Close the oven making sure the thermocouple wires are functioning.
[101] 8. Mark the start of the chart recorder.
[102] Apparatus: 1. Oven. 2. Ice. 3. Chart Recorder. 4. J-Thermocouples (3).
Results: 1. Cold
Retention Time: Elapsed time from <32 F to 50 F in decimal hours. 2. Heat Gain
Rate
(''F/Hr): (50 F ¨ 32 F) Elapsed Time = 18 F Elapsed Time
[103] In one test of the example insulating device, the heat gain rate equaled
1.4 degF/hr
assuming 26.5 quarts capacity and used 3.542Ibs of ice for the test.
[104] The ability of the insulating device 10 to withstand interior leaks can
also be tested to see
how well the insulating device maintains the contents stored in the storage
compartment or
receptacle 504. In one example test, the insulating device 10 can be filled
with a liquid, such
as water, and then can be inverted for a predetermined time period to test for
any moisture
leaks. In this example, the insulating device 10 is filled with a liquid until
approximately half
of a volume of the receptacle 504 is filled, e.g. 3 gallons of water, and the
closure 301 is then
closed fully to ensure that the slider body 303 is completely sealed into the
horseshoe-
shaped portion 308. The entire insulating device 10 is then inverted and held
inverted for a
time period of 30 minutes. The insulating device 10 is then reviewed for any
leaks.
[105] The insulating device 10 can be configured to withstand being held
inverted for 30 minutes
without any water escaping or leaving the receptacle 504. In alternative
examples, the
insulating device can be configured to withstand being held inverted for 15
minutes to 120
minutes without any water escaping or leaving the receptacle 504. To perform
this test, it
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may be helpful to lubricate the closure to ensure that the closure is
adequately sealed. For
example, as shown in Fig. 9, a horseshoe-shaped portion 308 of the closure 301
is provided
with lubricant 309.
[106] The strength and durability of the fabric forming the outer shell 501,
inner liner 500 and the
insulating layer 502 of the insulating device 10 may also be tested. In one
example, the test
can be devised as a puncture test. In particular, this test can be designed as
an ASTM D751-
06 Sec. 22-25 screwdriver puncture test. In one example, the insulating device
10 can
withstand 35 lbs to 100 lbs of puncture force.
[107] The handle strength and durability of the insulating device 10 can also
be tested. One such
example test is depicted in Fig. 10. As depicted in Fig. 10, the closure 310
can be fully closed,
one of the carry handles 210 can hooked to an overhead crane 600, and the
opposite carry
handle 210 is hooked to a platform 650, which can hold weight. In one example,
the
platform 650 can be configured to hold 200 lbs. of weight. During the test,
the crane 600 is
slowly raised, which suspends the insulating device 10 in a position where the
bottom plane
of the insulating device 10 is perpendicular with the floor. In one example,
the insulating
device 10 can be configured to hold 200 lbs. of weight for a minimum of 3
minutes without
showing any signs of failure. In alternative examples, the insulating device
can be configured
to hold 100 lbs. to 300 lbs. of weight for 1 to 10 minutes without showing
signs of failure.
[108] Figs. 11-15 show another example insulating device 2010. The example
insulating device
2010 can be of a similar construction to the above examples, where like
reference numerals
represent like features having similar functionality. However, the example
insulating device
2010 can also include a fold-down flap or portion 2307 to assist in insulating
the closure
2311 of the insulating device 2010. Specifically, the closure 2311, which can
be a zipper in
accordance with the other examples discussed herein, can be included on a fold-
down flap
or portion 2307 and can be front facing in that it is located on a front
surface or wall of the
insulating device 2010. The front facing closure 2311, can allow for
additional user access to
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the insulating device 2010, and the fold-down flap or portion 2307 can help to
provide
additional insulation at the closure 2311. In this example, when the fold-down
flap 2307 is
in the extended position and the closure 2311 is open or unsealed, the
contents in the
insulating device 2010 maintain the closure 2311 in the open position for
better access of
the contents of the insulating device 2010. This may assist the user to be
able to more easily
access the contents of the insulating device 2010. Also as shown in Fig. 11,
when the fold-
down flap 2307 is in the extended position, the insulating device 2010 can
approximate a
trapezoidal shape for providing an elongated closure at the top of the
insulating device
2010.
[109] As shown in the side and cross-sectional views, i.e., Figs. 12 and 14A,
the insulating device
2010 can approximate a pentagon, when the fold-down flap 2307 of the
insulating device
2010 is in an extended position. This general shape may provide for an
insulating device
2010 that may be easily shipped in that several insulating devices can be fit
into a shipping
container. Nevertheless, other shapes and configurations are contemplated
e.g., square,
rectangular, triangular, conical, curved, and frusto-shapes which may provide
an extended
closure at the top of the insulating device 2010 and that can be easily
packaged.
[110] Like in the above examples, the insulating device 2010 may include an
outer shell 2501, an
inner liner 2500 forming a storage compartment, a receptacle, or inner chamber
2504 and
an insulating layer 2502 positioned in between the outer shell 2501 and the
inner liner 2500.
The insulating layer 2502 provides insulation for the storage compartment
2504. The
closure 2311 can be configured to substantially seal an opening 2512, which is
located on an
angled front facing surface and extends through the outer shell 2501 and the
inner liner
2500 to provide access to the storage compartment 2504. Also, the closure 2311
can
include similar features and functionality in accordance with the examples
discussed above.
In one example, the closure 2311 can be a zipper and can be substantially
waterproof so as
to resist liquid from exiting the opening when the insulating device 2010 is
in any
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orientation. Also, similar to the above examples, the insulating device 2010
can be provided
with one or more of carry handles 2210, shoulder straps 2218, webbing loops
2224 formed
with threads 2222 by stitching for example, rings 2214, and attachment points
2213 which
can have similar features and functionality as in the examples above.
[111] As shown in Figs. 11 and 12 and as noted above, the fold-down flap 2307
may include the
front facing closure 2311 and can be folded over and secured to a sidewall of
the insulating
device 2010 to further insulate the front facing closure 2311. The fold-down
flap 2307 of the
fastening mechanism 2301 can include first and second end hooks or clips
2313a, 2313b. In
one example, each of the end clips 2313a, 2313b can include a slot 2317a,
2317b for being
received in corresponding loops 2315a, 2315b located on the sides or the
sidewalls of the
insulating device 2010. To close the insulating device 2010, the fold-down
flap 2307 along
with the front facing closure 2311 are folded over onto a front face or wall
of the insulating
device 2010. The fold-down flap 2307 folds over with and conceals or covers
the front
facing closure 2311. The fold-down flap 2307 is held into place by the first
and second end
clips 2313a, 2313b and maintains the fastening mechanism 2301 in the closed
position.
Additionally, when the fold-down portion 2307 is secured to the sidewalls of
the insulating
device 2010, the fold-down portion 2307 extends at least partly in a
substantially horizontal
direction, which orients a carrying handle 2318 in position for a user to
grasp for holding and
carrying the insulating device 2010. As in the other handles and straps, the
carry handle
2318 can be secured to the outer shell with a reinforcement patch (not shown).
The carry
handle 2318 can be provided on the rear surface of the insulating device 2010
to oppose the
closure 2311 on the front facing surface, which can be used by the user to
grasp during
opening and closing the insulating device 2010 to make it easier for the user
to open and
close the closure 2311. The carry handle 2318 may also be used for hanging the
insulating
device 2010, or for carrying the insulating device 2010; however, other uses
are also
contemplated.
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[112] Fig. 14A shows a cross-sectional side view of the insulating device
2010. The insulating
device 2010 includes an inner liner 2500, an insulating layer 2502, and an
outer shell 2501.
As shown in Fig. 14A, like in the above examples, the insulating layer 2502
can be located
between the inner liner 2500 and the outer shell 2501, and can be formed as a
foam
insulator to assist in maintaining the internal temperature of the receptacle
2504 for storing
contents desired to be kept cool or warm. Also the insulating layer 2502 can
be located in
between the inner liner 2500 and the outer shell 2501, and can be unattached
to either the
inner liner 2500 or the outer shell 2501 such that it floats between the inner
liner 2500 and
the outer shell 2501. In one example, the inner liner 2500 and the outer shell
2501 can be
connected at the top portion of the insulating device 2010 such that the
insulating layer
2502 can float freely within a pocket formed by the inner liner 2500 and the
outer shell
2501.
[113] In this example, the inner layer or inner liner 2500 can be formed of a
first inner liner
sidewall portion 2500a and a bottom inner liner portion 2500b. The first inner
liner sidewall
portion 2500a and the bottom inner liner portion 2500b can be secured
together, by for
example welding, to form the chamber 2504. Like in the above example, the
chamber 2504
can be a "dry bag," or vessel for storing contents. In one example, a tape,
such as a TPU
tape, can be placed over the seams joining the sections of the chamber 2504,
after the first
inner liner sidewall portion 2500a and the bottom inner liner portion 2500b
are secured or
joined together. The tape seals the seams formed between the first inner liner
sidewall
portion 2500a and the bottom inner liner portion 2500b to provide an
additional barrier to
liquid to prevent liquid from either entering or exiting the chamber 2504. The
inner liner
2500 can, thus, either maintain liquid in the chamber 2504 of the insulating
device 2010 or
prevent liquid contents from entering into the chamber 2504 of the insulating
device 2010.
It is also contemplated, however, that the inner liner 2504 can be formed as
an integral one-
piece structure that may be secured within the outer shell.
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[114] As shown in both Figs. 14A and 15, the insulating layer 2502 can be
formed of a first portion
or an upper portion 2502a, a second portion or base portion 2502b, and a base
support
layer 2505. In addition, the first portion 2502a can include a top flap or
smaller rectangular
shape 2502a1. When the fold-down flap 2307 is folded onto the top portion of
the
insulating device 2010, the top flap 2502a1 of the insulating layer together
with the
remainder of the first portion 2502a and the base portion 2502b surrounds
substantially all
of the inner chamber 2504 with insulation to provide a maximum amount of
insulation to
the inner chamber 2504 of the insulating device 2010.
[115] When the upper portion 2502a is rolled flat, the upper portion 2502a of
the insulating layer
2502 generally resembles a "T" shape such that the insulating layer defines a
first height Hi
and a second height H2 where the first height Hi is greater than the second
height H2. In this
example, a majority of the insulating layer can extend to the second height
Hz, which is less
than the first height Hi. Also, the first portion 2502a can be formed of two
inter-connected
rectangular shapes, where the bottom of the first portion 2502a forms a first
larger
rectangular shape 2502a2 and an upper section of the first portion 2502a forms
the top flap
2502a1 of the smaller rectangular shape. It is also contemplated that the
first larger
rectangular shape 2502a2 can be formed as a separate piece from the smaller
rectangular
shape 2502a1. The first rectangular shape 2502a2 can have a first rectangular
width and the
second rectangular shape 2502a1 can have a second rectangle perimeter and
first
rectangular shape 2502a2 width approximates the second rectangular shape
2502a1
perimeter. In one example, the smaller rectangular shape 2502a1 forms a top
flap of the
insulation layer of the upper portion 2502a, which extends into the fold-down
portion 2307.
[116] The first portion 2502a and the second portion 2502b can be formed of an
insulating foam
material as discussed herein. In one example, the second portion 2502b can be
formed of a
thicker foam material than the first portion 2502a. For example, the thickness
of the second
portion 2502b can be formed between 20 mm and 50 mm thick, and, in one
particular
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example, can be formed of a 38 mm thick foam, and the first portion 2502a can
be formed
between 15 mm and 30 mm, and, in one particular example, can be formed of a 25
mm thick
foam. In one example, the foam can be a NBR/PVC blended foam, a PVC free NBR
foam, or
other eco-friendly type foam.
[117] Also as shown in Fig. 15, a base support layer 2505 adds to the
insulation and the structural
integrity of the insulating device 2010 at base 2215. The base support layer
2505 may also
provide additional protection around the bottom of the insulating device 2010.
In one
example, the base support layer 2505 can be formed from EVA foam. The base
support layer
2505 may include a certain design such as a logo or name that can be molded or
embossed
directly into the material. A base support ridge 2400, which provides
structural integrity and
support to the insulating device 2010 can also be molded or embossed directly
into the base
support layer 2505. In one example, the base support layer 2505 and the base
portion
2502b can be detached or unsecured for ease of assembly in reducing the number
of
assembly steps. The base portion 2502b can be formed as an oval shape to close
off a lower
opening 2506 formed by the open shape of the upper portion 2502a.
[118] The bottom of the first portion 2502a maintains its form when folded
into an oval-cylindrical
shape and placed in between the inner liner 2500 and the outer shell 2501. The
insulating
layer 2502 maintains its shape which results in the basic oval-cylindrical
shape of the
insulating device 2010.
[119] The outer shell 2501 can be formed of an upper sidewall portion 2501a, a
lower sidewall
portion 2501b, and a base portion 2501c. Each of the upper sidewall portion
2501a, the
lower sidewall portion 2501b, and the base portion 2501c can be secured by
stitching.
Other securing methods are also contemplated, such as, using welds or
adhesives.
[120] Additionally, the fold-down portion 2307 can be at least partly free of
foam to make it easier
to close the fastening mechanism 2301. In particular, the fold-down portion
2307 can
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include a first section 2307a and a second section 2307b. The first section
2307a can be free
of the insulation layer 2502 and the second section can include the insulation
layer 2502.
[121] Referring to Fig. 1413, like in the above examples, the closure 2311 can
be mounted on a
backing or fabric. In the case of a zipper this can be referred to as zipper
tape 2306. Also,
like in the above examples, the zipper tape 2306 can be attached between the
inner liner
2500 and the outer shell 2501 and, in particular, the zipper tape 2306 can be
secured to the
upper sidewall portion 2501a of the outer shell and the first inner liner
sidewall portion
2500a. As shown in Fig. 1413, the zipper tape 2306, the upper sidewall portion
2501a of the
outer shell, and the first inner liner sidewall portion 2500a can form a
stacked arrangement
of a sandwich structure where the zipper tape 2306 is located between the
upper sidewall
portion 2501a of the outer shell and the first inner liner sidewall portion
2500a.
[122] The insulating device 2010 can be formed using similar techniques in
relation to the
examples as discussed above. For example, the upper sidewall portion 2501a of
the outer
shell 2501 can be formed. Also the base 2215 can be formed separately with the
base
portion 2502b of the insulation layer 2502, the base support layer 2505, the
lower sidewall
portion 2501b, and a base portion 2501c of the outer shell 2501 according to
the techniques
discussed herein. The base 2215 can be secured to the bottom of the upper
sidewall portion
2501a of the outer shell 2501 using the techniques discussed herein. The upper
portion
2502a of the insulation layer 2502 can be placed within the upper sidewall
portion 2501a of
the outer shell 2501. The first inner liner sidewall portion 2500a and the
bottom inner liner
portion 2500b can then be secured to form the inner liner 2500 and chamber
2504. Tape,
such as a TPU tape, can be placed over the seams joining the sections of the
inner liner 2500
and chamber 2504. The inner liner 2500 can then be placed within the
insulation layer 2502.
The closure 2311 can then be attached between the inner liner sidewall portion
2500a and
the upper sidewall portion 2501a. At this point in the process the insulating
device 2010
assembly will have a cylindrical shape with an open top. To close the open
top, the upper
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ends of the inner liner sidewall portion 2500a and the upper sidewall portion
2501a can then
be secured together by welding or by using any of the techniques discussed
herein to form
the insulating device 2010. A binding 2518 can be applied to the top portion
of the
insulating device 2010 to cover and conceal the seam between the outer shell
2501 and the
inner liner 2500. The loop patch (not shown), carry handles 2210, shoulder
strap 2218,
webbing loops 2224, and rings 2214 can be added to the outer shell 2501 by the
various
techniques discussed herein, after the formation of the outer shell or once
the insulating
device 2010 is formed. It is contemplated that the inner liner and the outer
liner can be
formed by welding, gluing, or stitching and combinations thereof.
[123] In another example, a magnetic connection can be implemented for
securing the fold-down
portion 2307 to the body of the insulating device 2010. As shown in Figs. 16A
and 1613, the
insulating device 2010 can be provided with a magnetic clip 3313, which can be
received by
a corresponding magnet (not shown) on the sidewall of the insulating device
2010.
However, it is also contemplated that the clip and clip receiving portion on
the insulating
device 2010 could be one or more of permanent magnets, metal strips, or
ferromagnetic
materials. In addition, other methods of securing the fold-down flap 2307 over
the front
facing closure 2311 are also contemplated. For example, one or more of hook
and loop,
buckle, snap, zipper, detent, spring loaded detent, button, cams, or threads
could be used
to secure the fold-down flap 2307 to the sidewall of the insulating device
2010.
[124] Figs. 17-22 show another exemplary insulating device 4010. The example
insulating device
4010 can be of a similar construction to the above examples and, in
particular, the example
discussed above in relation to Figs. 11-16B, where like reference numerals
represent like
features having the same or similar functionality. In this example, the
insulating device 4010
does not include a fold-down flap and can include a different overall shape
than the example
insulating device 2010. Additionally, the insulating layer 4502 can have a
different
configuration along with other variations that will be discussed below. Like
in the above
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example, the closure 4311 can be placed on a front face or wall of the
insulating device
4010.
[125] As shown in Figs. 18 and 19, when viewed from the front and rear, the
insulating device
4010 can generally form a trapezoidal shape, where the insulating device
diverges or tapers
upward toward the top of the insulating device 4010. The trapezoidal shape may
provide
certain insulation, user accessibility, and packaging benefits. For example,
the trapezoidal
shape can provide an extended period of ice coverage because of the additional
foam that
can be placed between the outer shell 4501 and the inner liner 4500 due to the
trapezoidal
shape.
[126] Additionally, the overall shape of the insulating device 4010 can help
to maintain the
insulating device 4010 in the opened position when the closure 4311 is in the
opened
position and permits the user to be able to easily access the contents of the
insulating device
4010. The trapezoidal shape as discussed herein also allows the closure 4311
to be formed
longer relative to the insulating device 4010. Other shapes that allow for an
extended
opening at the upper portion of the insulating device 4010 are also
contemplated. For
example, the upper portion of the insulating device 4010 could be formed with
an extended
curvature either upward or downward to allow for a larger closure extending
across the
upper portion of the insulating device 4010. Also as shown in Fig. 20, when
viewed from the
side, the insulating device 4010 can be formed generally conical, tapered or
funnel-shaped
such that the sides converge to the top of the insulating device 4010. Also
the sides can be
formed substantially parabolic in shape in certain examples. Therefore, the
insulating device
4010 converges to an apex along the top of the insulating device 4010 as
opposed to an oval
shape with the same perimeter as the bottom of the insulating device 4010.
[127] In certain examples, a trapezoidal shape may also provide for an
insulating device 4010 that
may be easily shipped in that several insulating devices 4010 can be fit into
a shipping
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container. For example, multiple insulating devices 4010 could be arranged in
a shipping
container in different orientations so as to utilize more space within a
shipping container.
[128] In alternative embodiments, when the closure 4311 is in the opened or
unsealed position,
the contents in the insulating device 4010 may maintain the closure 4311 in
the open
position for easier access to the contents of the insulating device 4010. In
this example, the
weight of the contents can force a lower half of the closure 4311 away from an
upper half of
the closure 4311 such that the user can better see the contents of the
insulating device 4010
and more easily remove the contents or add contents to the insulating device
4010.
[129] In this example, the outer shell construction, insulating layer, and the
inner liner
construction can be similar to that of the embodiment discussed above in
relation to Figs.
11-16B, the details of which are not repeated here. The outer shell 4010 may
also include a
top portion 4316, which is configured to receive the closure 4311 therein. The
top portion
4316 can be formed of the same material as the remaining outer shell 4501,
which in one
specific example, can be nylon and specifically an 840d nylon with TPU.
[130] Similar to the example discussed in relation to Figs. 11-16B, the
insulating device 4010 can
be provided with one or more of carry handles 4210, a shoulder strap 4218,
webbing loops
4224, which are formed by threads 4222, rings 4214, and attachment points 4213
which can
have similar features and functionality as in the examples above.
Additionally, a rear carry
handle 4318 can be provided on the rear surface of the insulating device 4010
to oppose the
closure 4311, which can be used by the user to grasp during opening and
closing the
insulating device 4010 to make it easier for the user to open and close the
closure 4311. The
rear carry handle 4318 may also be used for hanging the insulating device 4010
for drying
the inner chamber 4504, or for carrying the insulating device 4010. Each of
the carry
handles 4210, shoulder strap 4218, webbing loops 4224, and attachment points
4213 can be
reinforced by one or more of additional structures in the form of webbing or
suitable
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polymeric materials. This reinforcement material may be applied to any of the
examples
discussed herein.
[131] Also as shown in Figs. 17 and 21 a binding 4518 can be included that
extends over the top of
the insulating device 4010 to secure the outer shell 4501 to the inner liner
4500. The
binding 4518 can be folded over the top of the insulating device 4010 and then
stitched over
the over outer shell 4501 and the inner liner 4500 to form a cover to the
joint or seam
between the inner liner 4500 and the outer shell 4501. As shown in Fig. 18,
the binding
4518 can be folded into thirds to form a first folded portion 4518a where the
first third is
attached to a first side of the insulating device 4010, the second third is
extends over the top
of the insulating device 4010, and the last third is attached to a second side
of the insulating
device 4010. The binding 4518 covers the seam between the outer shell 4501 and
the inner
liner 4500 along the top of the insulating device 4010. Also, as shown in Fig.
17, the binding
4518 extends from the top of the insulating device 4010 and forms a second
folded portion
4518b where the binding 4518 is folded in half and a third unfolded portion
4518c, which
forms and extends to attachment points 4213 that receive rings 4214. Each side
of the
insulating device 4010 can include a second folded portion 4518b and a third
unfolded
portion 4518c such that the insulating device 4010 can include two second
folded portions
4518b and two third unfolded portions 4518c. The binding 4518 can unfold
closer to the
attachment points 4213 and may also be formed unfolded from the attachment
points 4213
to the top of the insulated device 4010. In either of these configurations, a
section of the
binding 4518, e.g., the second folded portion 4518b, can be unattached to the
insulating
device 4010 and forms a strap between the folded portion 4518a and the
attachment points
4213. In this example, two straps can be formed by the two second unfolded
portions
4518b and can be grasped by the user for handling the insulating device, can
be used for
hanging the insulating device 4010 for drying, and the like. Also, the
attachment points 4213
formed by the binding 4518 can be a loop or slot for receiving the rings 4214.
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[132] Figs. 22 and 22A show the insulating layer 4502 in additional detail,
which is similar to the
example insulating device 4010 discussed above where like reference numerals
represent
like components with the same or similar functionality. The insulating layer
4502 can be
formed of the materials as discussed herein and, in certain examples, can be
PVC free and/or
can have non-thermoset properties such that the foam is fully resilient. Like
the above
examples, the upper portion 4502a of the insulating layer 4502 can be formed
of a single
sheet of material which is rolled into the shape defined by the opening
between the inner
liner 4500 and the outer shell 4501. As shown in Fig. 22, the insulating layer
4502, like in the
above examples, can be formed of a first portion or an upper portion 4502a and
a second
portion or base portion 4502b. The rear top flap 4502a1 can be formed in
smaller
rectangular shape. The rear top flap 4502a1 extends higher than the front side
of the first
portion 4502a of the insulating layer 4502a to accommodate for the front
facing closure
4311. Specifically, the rear top flap 4502a1 can extend to a first height H3,
and the first
portion 4502a can extend to a second height H4, and the first height H3 can be
greater than
the second height H4. Additionally, as shown in Fig. 22, a majority of the
insulating layer
4502 can extend to the second height H4. Alternatively, as shown in Fig. 22A,
the rear half of
the insulating layer 4502 can extend to the first height H3 and the front half
of the insulating
layer 4502 can extend to the second height H4. Additionally, as shown in Fig.
22A, the
insulating layer 4502 can taper from the first height H3 to the second height
H4 Also, this
provides the areas of the insulating layer 4502 near the top with tapered or
chamfered
portions along the sides of the insulating device 4010 to provide a smaller
profile on each
side of the insulating device 4010.
[133] In one example, the first portion 4502a can define a first area Ai, and
the rear top flap
4502a1 can define a second area Az, which is smaller than the first area Al.
When installed
between the inner liner 4500 and the outer shell 4501, the insulating layer
4502 generally
follows the conical and trapezoidal shape of the profile of the insulating
device 4010.
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Additionally, the upward tapered profile of the outer shell 4501 and the inner
liner 4500 can
help to position the insulating layer 4502 such that the insulating layer
covers a majority of
the inner liner 4500.
[134] In particular, as shown in Fig. 21, the insulating layer 4502 occupies a
majority of the space
formed between the inner liner 4500 and the outer shell 4501. The insulating
layer 4502
extends substantially to the top of the insulating device 4010 in both the
front and the rear
portions of the insulating device 4010 to insulate a majority of the
compartment 4504. As a
result, the insulating layer 4502 surrounds substantially the entire inner
chamber 4502 to
provide a maximum amount of insulation to the inner chamber 4504 of the
insulating device
2010. In one example, the insulating layer 4502 covers 80% or more of the
inner liner 4500
covering the inner chamber 4504, and in particular examples the insulating
layer 4502
covers 85%, 90%, or 95% or more of the inner liner 4500 covering the inner
chamber 4504.
[135] In the examples discussed in relation to Figs. 11-22, the front facing
closures 2311, 4311 can
be formed such that they extend a majority of the way along the front facing
surface of the
insulating devices 2010, 4010. As discussed above, the front-facing closures
2311, 4311 can
be formed as zipper closures in accordance with the examples discussed herein.
In one
example, the closures 2311, 4311 can be substantially waterproof or highly
water resistant
and can be water tight and air tight. The front facing closures 2311, 4311 can
be formed as
long as possible in the front facing surface of the insulating devices 2010,
4010 to provide for
extended user accessibility and visibility of the contents stored in the
insulating devices
2010, 4010. In one example, the closures 2311, 4311 can define a first length
Li, and the top
portion of the insulating device 4010 can define a second length L2.
[136] In one example, L2 can be 3 cm to 10 cm longer than Li, the length of
the front facing
closures 2311, 4311 and in one specific example can be 5 cm longer than the
front-facing
closures 2311, 4311. The closures 2311, 4311 first length Li can extend at
least 80% of the
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second length L2 and up to 98% of the second length L2. In one particular
example, the
length of the closures 2311, 4311, Li can extend across 87% of the second
length L2.
[137] Additionally, the length Li of the front-facing closures 2311, 4311 can
be formed longer than
the length L3 of the bases of the insulating devices 2010, 4010. In certain
examples, the
front facing closures 2311, 4311 can be formed approximately 1% to 25% longer
than the
length L3 of the bases of the insulating devices 4010. In one specific example
the length Li of
the front facing closures 2311, 4311 can be 10% longer than the length L3 of
the bases. For
example, the front-facing closures length Li can be formed 3 cm to 12 cm
longer than the
length L3 of the bases of the insulating devices, and, in one particular
example, the length Li
of the front facing closures 2311, 4311 can be 5 cm longer than the length L3
of the base.
[138] In still other embodiments, the insulating device can include a closure
that extends around
the entire perimeter or a majority of the perimeter of the insulating device
and a front
facing closure 2311, 4311 as discussed above. In this particular example, the
contents of the
insulating device can be easily accessed by the user once the entire or a
majority of the top
portion is removed or through the closure 2311, 4311.
[139] In another example, the insulating device can be formed modular such
that the top and/or
the bottom can be removed and multiple structures can be interconnected to
form larger or
smaller insulating devices. For example, the insulating device can be formed
of different
sections by way of removable fasteners, such as snaps, zippers, threads,
seals, hook and
loop, and the like.
[140] In relation to the examples discussed herein, a series of vents can be
provided along the
outer shells of the insulating devices. The vents allow for any gases that are
trapped
between the inner liner and the outer shell to escape. Without the vents, the
gases trapped
between the inner liner and the outer shell can cause the insulating device to
expand, which
in certain instances, may not be desired. In certain examples, the one or more
joints or
seams that connect the various portions of the outer shell provide vents for
gases. Vents
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can be provided in areas of the outer shell where the outer shell fabric is
pierced. For
example, tiny openings can be provided at any of the stitching locations where
the various
components are located on the insulating devices. Specifically, the vents can
be provided in
the areas where the handles, molle loops, straps, reinforcement patches,
bindings, D-rings,
loop patches, etc. are attached to the outer shell of the insulating device.
For example,
stitching that may be used to secure these components to the outer shell
provides openings
into the outer shell, which creates venting between the insulation layer and
the outer shell.
In one specific example, the insulating device may vent through binding 4518.
[141] The example insulating device 4010 was tested to determine ice
retention. As such, the ice
retention testing may be utilized to determine insulative properties of
example insulating
device 4010. In an exemplary test, the duration of the increase from 0 F to 50
F when the
insulating device 4010 was filled with ice was determined according to the
test parameters
below. In certain examples, the temperature of the insulating device increases
from 10 F to
32 F in a duration of 24 hours to 24 hours, the temperature of the insulating
device
increases from 32 F to 50 F in a duration of 36 hours to 68 hours, and the
temperature of
the insulating device increases from 0 F to 50 F in a duration of 70 hours to
90 hours.
[142] The ice retention was tested using the following test. More than 24
hours before the test,
the following steps are performed:
= Ensure test coolers are clean inside and out.
= Mark test coolers with unique identifier and record identifier and
description in test log
or notes.
= Using duct tape, place a thermocouple (T) in the approximate center of
the test cooler
(C).
= The thermocouple tip should be approximately 1 inch above the cooler
floor. (See Fig.
23 for an example of proper thermocouple set-up.)
= Condition test coolers by keeping test coolers inside (ambient
temperature 65-75 F)
with lids open for a minimum of 24 hours.
= Calculate the amount of ice required for testing (to nearest 0.1 lbs.)
using the equation
below.
o Ice per cooler = 0.52 lbs. x Quart capacity of cooler
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o Ice required = Ice per cooler x number of coolers
= Condition the ice by placing the ice in a freezer (-15 to -5 F) for a
minimum of 24 hours
prior to use.
[143] The day of the test, the following steps are performed:
= Gather Test Equipment
= Allow thermal chamber to reach a temperature of 100 F
= Scale ¨ place scale near freezer with test ice
= Data Logger ¨ ensure Data Logger has charged battery
[144] The test procedure is as follows:
= Bring test coolers to freezer with test ice.
= Place test cooler on scale and tare the scale.
= Break test ice with hammer.
= Using the scale as reference, quickly fill the test cooler with the
required amount of ice.
= Ensure that the ice is evenly distributed throughout the test cooler.
= Ensure that the connector end of the thermocouple is outside of the test
cooler and
close and secure the cooler lid.
= Repeat steps for the remaining test coolers.
= Arrange the coolers in the test area such that they all have even amounts
of direct
sunlight and airflow (one cooler does not block the other).
= Connect all thermocouples to the data logger.
= Check all thermocouple readings to ensure that all connections are
complete and the
channels are recording properly. (Note: The starting temperature inside each
test
cooler should be < 10 F).
= Power up the data logger and configure to record with temperatures
recorded at less
than 10 minute intervals.
= Begin recording and note time in test log.
= Allow the test to continue until the inside temperature of each test
cooler is 50 F.
= Stop recording.
= Disconnect thermocouples from data logger.
= Receive data from data logger.
= Remove test coolers from test area.
= Empty test coolers and allow them to dry.
= Remove thermocouples from test coolers
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[145] The heat gain rate of the insulating devices 2010, 4010 can be
approximately 0.5 to 1.5
degF/hr, and, in one particular example, the heat gain rate can be
approximately 1.0
degF/hr.
[146] Like in the above examples, the ability of the insulating devices 2010
and 4010 are also
configured to withstand interior leaks and were also tested to see how well
the insulating
devices 2010, 4010 maintain the contents stored in the storage compartment or
receptacles
2504, 4504. In one example test, the insulating devices 2010, 4010 can be
filled with a
liquid, such as water, and then can be inverted for a predetermined time
period to test for
any moisture leaks. In this example, the insulating devices 2010, 4010 are
filled with a liquid
until approximately half of a volume of the receptacle 4504 is filled, e.g. 3
gallons of water,
and the closures 2301, 4301 are then closed fully. The entire insulating
devices 2010, 4010
are then inverted and held inverted for a time period of 30 minutes. The
insulating devices
2010, 4010 are then reviewed for any leaks.
[147] The insulating devices 2010, 4010 can be configured to withstand being
held inverted for 30
minutes without any water escaping or leaving the receptacles 2504, 4504. In
alternative
examples, the insulating devices 2010, 4010 can be configured to withstand
being held
inverted for 15 minutes to 120 minutes without any water escaping or leaving
the
receptacles 2504, 4504.
[148] Figs. 24-32 show another example insulating device 3010. The example
insulating device
3010 can be of a similar construction to the above examples, where like
reference numerals
represent like features having similar functionality. In this example, as can
be seen in Figs.
24-26 and 32, the closure 3311 and opening 3512 is formed through a first
sidewall 3507A,
a second sidewall 370513, and a third sidewall 3507C and partially through a
fourth sidewall
3507D of the insulating device 3010. Moreover, the opening 3512 is configured
to provide
access to the inner chamber 3504 as is shown in Figs. 29A and 32. Like in the
above
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examples, the closure 3311 can be substantially waterproof so as to resist
liquid from exiting
the opening 3512 when the insulating device 3010 is in any orientation.
[149] As shown in the cross-sectional view of Fig. 29A, the example insulating
device 3010
generally includes a body assembly 3350 and a lid assembly 3300, which
together form the
three main components of the insulating device 3010: the inner liner 3500, the
insulating
layer 3502, and the outer shell 3501. The inner liner 3500 can, in one
example, be formed of
double laminated TPU nylon fabric, the insulating layer 3502 can, in one
example, be formed
of can be formed of NIBR/PVC foam blend or any other suitable blend or foam,
and the outer
shell 3501 can, in one example, be formed of TPU nylon fabric. It is also
contemplated that
the inner liner and the outer shell 3501 can be formed of one or more of PVC,
TPU coated
nylon, coated fabrics, and other weldable and/or waterproof fabrics.
[150] As shown in Figs. 24-26, the closure 3311 extends between the body
assembly 3350 and the
lid assembly 3300 to substantially seal the body assembly 3350 and the lid
assembly 3300
from water. Additionally, as shown in Fig. 29A, the lid assembly 3300 can be
connected to
the body assembly 3350 by the outer shell 3501, which forms a living hinge
3503. In one
example, the living hinge 3503 can be formed as a portion of the outer shell
3501 and/or the
inner liner 3500 and specifically from the flexible nature of the material of
the outer shell
3501 and/or the inner liner 3500 to provide a larger opening in the insulating
device 3010.
The living hinge 3503 can also be reinforced by an inner piece of fabric
3503A, which can be
formed of the inner liner material or other waterproof materials. In this way,
the chamber
3504 and contents of the insulating device 3010 can be accessed by opening the
closure
3311 and folding back or opening the lid assembly 3300.
[151] In this example, the insulating device 3010 can be in the shape of a
cuboid or prism. For
example, the outer shell 3501, the insulating layer 3502, and the inner liner
3500 define the
first sidewall, 3507A, the second sidewall 350713, the third sidewall 3507C,
and the fourth
sidewall 3507D of the cuboid. Also the lid assembly 3300 forms a top wall
3300a and the
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base 3215 forms a bottom wall 3215a to enclose the cuboid. However, the
contents of the
insulating device 3010 are accessed through the opening 3512 formed at the top
of the
insulating device and again can extend through each of the first sidewall,
3507A, the second
sidewall 3507B, the third sidewall 3507C and can extend partly through the
fourth sidewall
3507D. Other shapes are also contemplated for the insulating device 3010, for
example,
cylindrical, spherical, conical, pyramidal, frusto-conical, frusto-spherical,
frusto-pyramidal,
etc. The height of the insulating device 3010 can, in one example, be in the
range of 15 cm
to 50 cm and in one particular example can be 29 cm. The length of the
insulating device
3010 can be in the range of 15 cm to 50 cm and in one particular example can
be 32 cm.
Also the width of the insulating device can, in one example, be in the range
of 15 cm to 50
cm and in one specific example be 25.5 cm. The storage capacity of the
insulating device
3010 can be 10 to 15 quarts and in one particular example can be 12.7 quarts.
However, it is
contemplated that the insulating device 3010 may comprise any height, length,
width and
volume dimensions, without departing from the scope of these disclosures.
[152] Like in the above examples, the insulating device 3010 can include one
or more handles
3210, 3212, rings 3214, and webbing loops 3224 for attaching various items,
e.g. straps
(shoulder), carabineers, dry bags, keys, storage cases, etc. The rings 3214
can be D-rings,
and a shoulder strap (not shown) can be connected to the D-rings for easy
carrying of the
insulating device. Also the rings 3214 can be attached to the insulating
device 3010 at
attachment points 3213, which can form loops or straps 3315a that also form a
slot for
receiving the rings 3214. The insulating device may also include side, front
and/or rear carry
handles, pockets, tie downs, and D-rings anywhere on the external surface of
the outer shell.
The pockets can be sized for receiving keys, phones, wallets, etc. and can be
formed
waterproof. The pockets may also include a waterproof zipper to prevent the
contents
therein from getting wet.
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[153] Likewise, similar to the above examples, the outer shell 3501 can
also include multiple
reinforcement areas or patches 3320 that are configured to assist in
structurally supporting
the optional handles, straps, and webbing loops (e.g. 3210, 3212, 3213, 3214,
and 3224).
The handles or straps (e.g. 3210, 3212, 3213, 3214, and 3224) and other
attachments can be
stitched to the patches using threads 3222. In certain examples, these threads
3222 do not
extend through the outer shell 3501 into the insulating layer 3502. The
optional handles or
straps can be sewn to the patches 3320, and the patches 3320 can be RE welded
to the
outer shell 3501. Also, in other examples, the patches 3320 can be sewn or
adhered to the
outer shell 3501. Apertures from the stitching operation can provide venting
to the interior
defined by the outer shell 3501 and the inner liner 3500 of the insulating
device 3010. In
addition, other techniques are contemplated for securing the handles or straps
to the
insulating device 3010.
[154] The internal components of the insulating device 3010, the body assembly
3350, and the lid
assembly 3300 can be seen in the cross-sectional view of Fig. 29A. In
addition, Fig. 298
shows a magnified cross-sectional view of the lid assembly 3300.
[155] The lid assembly 3300 includes an upper inner liner portion 3500A, an
upper insulating layer
portion 3502A and an upper outer shell portion 3501A. The upper insulating
layer portion
3502A can be formed of a single layer of foam, which corresponds to the
overall shape of
the lid assembly 3300. The foam can, in one example, be an insulating foam, as
discussed
herein, which can be the same foam as is used in the body assembly 3350, and
can be
unattached to and floating between the upper inner liner portion 3500A and the
upper
outer shell portion 3501A. As shown in Fig. 298, the upper inner liner portion
3500A can be
formed of a sheet of material 3500A1 and a strip of material 3500A2 that is
attached to the
binder 3518. In other embodiments the sheet of material 3500A1 can connect
directly to
the binder 3518 thus eliminating the need for the strip of material 3500A2.
The strip of
material 3500A2 can overlap and be welded to the sheet of material 3500A1.
Seam tape
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3509 can be placed over the connection between the sheet of material 3500A1
and the strip
of material 3500A2. It is also contemplated that the upper inner liner portion
3500A can be
formed as a unitary structure by injection molding, for example.
[156] The upper inner liner portion 3500A can be connected to the upper outer
shell portion
3501A by joining the upper inner liner strip of material 3500A2 to an upper
outer shell strip
of material 3501A3 at a RE weld joint 3522. However, it is contemplated that
other types of
securing methods could be used such as other forms of welding, stitching,
adhesives, rivets,
etc. Additionally, as will be discussed in further detail, a binding material
3518, in the form
of a strip or band can be sewn over the ends of the upper inner liner strip of
material
3500A2 and the upper outer shell strip of material 3501A3. It is also
contemplated that the
binding material 3518 can be coupled over the ends of the upper inner liner
strip of material
3500A2 and the upper outer shell strip of material 3501A3 by a plurality of
rivets, or by using
one or more adhesives.
[157] As shown in Figs. 29A and 298, the upper outer shell portion 3501A of
the lid assembly 3300
may include two separate layers 3501A1, 3501A2 and an upper outer shell strip
of material
3501A3 extending perpendicular to the two separate layers 3501A1, 3501A2. The
upper
outer shell strip of material 3501A3 can be integral and attached to a first
outer shell section
3501131 as discussed in further detail below. For example, the upper outer
shell strip of
material 3501A3 and the first outer shell section 3501131 can be formed or cut
from the
same material. However, it is also contemplated that outer shell strip of
material 3501A3
and the first outer shell section 3501131 are formed of separate structures or
different
materials. In one example, the top layer 3501A1 can be formed of a TPU coated
nylon
laminate, and the bottom layer 3501A2 can be formed of a compression molded
EVA
material. The upper outer shell portion 3501A may also be formed of a unitary
piece of
material in an injection molding process, for example.
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[158] As shown in Figs. 29A and 298, the binding material 3518 can both secure
the lid assembly
3300 together and secure the lid assembly 3300 to the body assembly 3350. The
binding
material 3518, in certain examples, can be formed of a strip, band or ribbon
and can be
made of nylon. It is contemplated that the binding material 3518 can be formed
from
additional or alternative polymers, without departing from the scope of these
disclosures.
Specifically, the first outer shell section 3501131 can be secured together
with the upper
inner liner 3500A, the separate layers 3501A1, 3501A2, and the upper outer
shell strip of
material 3501A3 of the upper outer shell portion 3501A by stitching the
binding material
3518 around the perimeter of the lid assembly 3300. The stitching, therefore,
extends
through the binding material 3518, the lower outer shell portion 350113, the
upper inner
liner portion 3500A, the top layer 3501A1, the bottom layer 3501A2 and the
strip of material
3500A2 to form a seam 3517.
[159] The weld joint 3522 can also both secure the lid assembly 3300 together
and secure the lid
assembly 3300 to the body assembly 3350. As alluded to above, the weld joint
3522, which
can be an RF weld joint, also secures the lid assembly 3300 together by
connecting the
upper inner liner portion 3500A and the upper outer shell portion 3501A by
joining the
upper inner liner strip of material 3500A2 to an upper outer shell strip of
material 3501A3.
It is also contemplated, however, that the joint 3522 could be formed by
stitching or by an
adhesive. Again once the lid assembly 3300 and the body assembly 3350 are
secured
together, the living hinge 3503 is formed between the lid assembly 3300 and
the body
assembly 3350.
[160] The lid assembly 3300 and the body assembly 3350 are also connected by
the closure, which
as discussed below, in one example, can be a zipper. Specifically, zipper tape
3306 can be
attached between the upper outer shell strip of material 3501A3 and the first
outer shell
section 3501131 of the lower outer shell portion 350113 by stitching, welding,
adhesives, etc.
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In this way, an upper portion 3306a and a lower portion 3306b of the zipper
tape 3306
secures the lid assembly 3300 and the body assembly 3350 together.
[161] Referring again to Fig. 29A, the body assembly 3350 includes lower inner
liner portion
350013, lower insulating layer portion 350213, and lower outer shell portion
350113. The lower
inner liner portion 350013 can be formed of a top strip 3500131, a middle
portion 350082, and
a bottom portion 350083. The top strip 3500131, the middle portion 350082, and
the
bottom portion 350083 can be welded or stitched together at seams 3508. The
seams 3508
can be covered with a seam tape 3509, which can be formed of a waterproof or
water
resistant material, such as PU (polyurethane). However, the seam tape 3509 can
be formed
of a breathable material that is impervious to water but allows gases to
escape from the in
the inner chamber 3504.
[162] In an alternative example, the lower inner liner portion 350013 can be
formed of a single
integral piece by, for example, injection molding. Fig. 31 shows an example
inner liner
portion 750013 that is formed by an injection molding process. In this
example, the lower
inner liner portion 750013 can be formed of one or more of urethane, PVC, TPU,
or other
weld-able material. The lower inner liner portion 750013 can be welded into
place onto the
outer shell, after the lower insulating layer is placed within the outer
shell.
[163] Referring again to Figs. 29A and 30, the lower insulating layer portion
350213 can include a
first sheet of insulating material 3502131 and a second sheet of insulating
material 350282.
Similar to the above examples, the first sheet of insulating material 3502131
and the second
sheet of insulating material 350282 can be free floating layers of insulating
material that are
not attached to either the lower inner liner portion 350013 or the lower outer
shell portion
350113. However, it is also contemplated that the first sheet of insulating
material 3502131
and the second sheet of insulating material 350282 can be attached to either
the lower
inner liner portion 350013 or the lower outer shell portion 350113. Moreover,
it is also
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contemplated that the lower insulating layer portion 350213 be formed of a
single unitary
piece.
[164] The lower outer shell portion 350113 can be formed of several sections.
In this example, the
lower outer shell portion 350113 can include a first outer shell section
3501131, a lower outer
wall section 350162, a first base layer 350163, and a second base layer
350164. Similar to
the lid assembly, the first base layer 350163 can be formed of a TPU coated
nylon laminate,
and the second base layer 350164 can be formed of a compression molded EVA
material.
Each of the lower outer wall section 350162, the first base layer 350163, and
the second
base layer 350164 can be joined together by stitching, welding or adhesives.
Also like in the
above examples, a base support ridge 3400 can be formed into the first base
layer 350163
and the second base layer 350164 to provide for structural integrity and
support to the
insulating device 3010 when the insulating device 3010 is placed onto a
surface. In
alternative examples, the lower outer shell portion 350113 can be formed as a
singular
component and may, in certain examples, be formed by an injection molding
process.
[165] Like in the above examples, the closure 3311 can be a zipper and can be
substantially
waterproof. Moreover, the zipper may comprise a pull tab or handle 3302, which
in this
example can formed of a hard plastic. It is also contemplated that the pull
tab 3302 can be
formed of a metal or alloy, a flexible polymer, cloth, string, or rope, among
others. Forming
the pull tab 3302 of a cloth, string, or rope may prevent the wear of the
connection between
the pull tab 3302 and the zipper. Specifically, when the zipper is closed
about the
circumference of the outer shell 3501, the pull tab 3302 can be rotated or
twisted by the
user. The cloth, string, or rope can withstand the twisting action by the
user. Other pull
tabs are also contemplated. For example, the pull tab could be provided with a
bearing
connection that allows the pull tap to be rotated 360 in all directions.
[166] A series of vents can be provided along the outer shell 3501 of the
insulating device 3010.
The vents allow for any gases that are trapped between the inner liner 3500
and the outer
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shell 3501 to escape. Without the vents, the gases trapped between the inner
liner 3500
and the outer shell 3501 will cause the insulating device 3010 to expand,
which in certain
instances, may not be desired. In certain examples, the joint or seams that
connect the
inner liner and the outer shell provides a vent to gases.
[167] The venting can be provided in the lid assembly 3300. Specifically in
the lid assembly 3300,
the seam 3517 may provide a series of small openings in the lid assembly 3300
where the
stitching on the binder material 3518 occurs. These openings act as vents for
gases to
escape the inner volume of the lid assembly 3300.
[168] Moreover, venting can be provided in the body assembly 3350. In the body
assembly, the
vents can be provided in areas of the lower outer shell portion 350113 where
the lower outer
shell portion 350113 fabric is pierced. For example, as shown in Fig. 26, tiny
openings can be
provided at the box and cross-shaped stitching 3521 where the rear carry
handle 3210 is
attached to the insulating device 3010. The vents can also be provided in the
areas or
locations where the handles 3212, 3210, molle loops 3224, and D-rings 3214 are
attached to
the outer shell 3501 of the insulating device 3010. For example, the stitching
that secures
the handles, webbing or molle loops 3224, and D-rings 3214 to the outer shell
provides
openings into the outer shell 3501 to create venting to the storage
compartment or inner
chamber 3504 of the insulating device 3010. Fig. 33 shows an example schematic
where
stitching 3519 extends through the outer shell 3501, a handle 3212 a
reinforcement areas or
patches 3320.
[169] To form the insulating device 3010, the body assembly 3350 can be formed
and then the lid
assembly 3300 can be formed by joining the lid assembly 3300 to the body
assembly 3350.
To form the body assembly 3350 of the insulating device 3010, the lower outer
shell portion
350113 and the lower inner liner portion 350013 can be formed independently.
Once the
lower outer shell portion 350113 is formed, the insulating layer 3502 can then
be placed
within the lower outer shell portion 350113. The lower inner liner portion
350013 can be
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attached to the lower outer shell portion 3501B to secure the insulating layer
3502 within
the lower outer shell portion 3501B and the lower inner liner portion 3500B.
However, the
insulating layer 3502 can freely float between the lower outer shell portion
3501B and the
lower inner liner portion 3500B. The lid assembly 3300 can be secured together
and the lid
assembly 3300 can be secured to the body assembly 3350 by welding the upper
inner liner
portion 3500A to the upper outer shell portion 3501A and the lower outer shell
portion
3501B at the weld joint 3522. Finally, the lid assembly 3300 can be further
attached to the
lower outer shell portion 3501B by way of stitching the top portion of the
lower outer shell
portion 3501B together with the top layer 3501A1, the bottom layer 3501A2, the
upper
inner liner portion 3500A, the strip of material 3501A3, and the binding
material 3518.
[170] Specifically, the lower outer shell portion 3501B can be formed by
attaching each of the first
outer shell section 350161, the lower outer wall section 3501132, the first
base layer 3501133,
and the second base layer 3501134 together. Next, each of the first sheet of
insulating
material 3502B1 and the second sheet of insulating material 3502132 can be
placed within
the lower outer shell portion 3501B. The lower inner liner portion 3500B can
then be
formed by welding each of the top strip 350061, the middle portion 3500132,
and the bottom
portion 3500133 together and then by adding the seam tape 3509 over each of
the welds.
Alternatively, as discussed above, the lower inner liner portion 3500B can be
formed by
injection molding the material. Once the lower inner liner portion 3500B is
formed, the
inner liner portion 3500B can be placed within the lower insulating layer
portion 3502B, and
the inner liner portion 3500B can be welded to the lower outer shell portion
3501B at seam
3511 all along the inner perimeter of the body assembly 3350 of the insulating
device 3010.
The seam 3511 can be formed in this example by either welding or stitching.
[171] Fig. 9 shows an exemplary welding technique that can be used to weld the
lower inner liner
portion 3500B to the lower outer shell portion 3501B. Once the lower inner
liner portion
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350013 is placed within the lower insulating layer portion 350213, the lower
inner liner portion
350013 can then be joined to the lower outer shell portion 350113 on its side
using a three-
piece tool, which can include a top U-shaped portion 3514A, a plate portion
3516, and a
bottom U-shaped portion 351413. The curvature of the top U-shaped portion
3514A, the
plate portion 3516, and the bottom U-shaped portion 351413, can correspond to
the shape of
the perimeter of the body assembly 3350 of the insulating device 3010.
[172] To form the seam 3511 as a weld, the lower inner liner portion 350013 is
placed into contact
with the lower outer shell portion 350113 and the plate portion 3516 is placed
within the
lower inner liner portion 350013 and the top U-shaped portion 3514A, and the
bottom U-
shaped portion 351413 can be placed into contact with lower outer shell
portion 350113. The
top U-shaped portion 3514A and the bottom U-shaped portion 351413 can be
connected to
two lead wires such that current can pass through the top U-shaped portion
3514A, the
lower outer shell portion 350113 and the lower inner liner portion 350013.
Current can then
be applied first to the top U-shaped portion 3514A to form a weld along the
top U-shaped
portion 3514A including the curves and the straight portions. After the top
section is
welded, the polarity of the lead wires can then be reversed to then weld the
bottom section
along the bottom U-shaped portion 351413.
[173] After the bottom section is welded by the bottom U-shaped portion the
remaining two sides
can then be welded by using the plate portion 3516 and a pair of straight side
bars or
another clamping mechanism or vice. Similar to the curved portions of the body
assembly
3350, current can be applied to the pair of straight side bars by lead wires.
Again, the sides
can be welded separately by applying the current in a first direction to weld
a first side and
by then switching polarity of the leads and running the current in the
opposite direction to
weld a second side. In one example, each of the sections can be welded for
approximately
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seconds. Once the weld is complete around the entire perimeter of the body
assembly
3350, the body assembly 3350 can be assembled to the lid assembly 3300.
[174] In one example, the closure 3311 can be substantially waterproof so as
to resist liquid from
exiting the opening when the insulating device is dropped from a distance of
six feet. In this
test, the insulating device can be filled completely with water and then
dropped from six
feet onto a concrete surface on each of the faces of the insulating device
3010, which in this
case is six.
[175] The example insulating device 3010 was tested to determine ice
retention. As such, the ice
retention testing may be utilized to determine insulative properties of
example insulating
device 3010. In an exemplary test, the duration of the increase from 0 F to 50
F when the
insulating device 3010 was filled with ice was determined according to the
test parameters
below. In certain examples, the temperature of the insulating device increases
from 0 F to
10 F in a duration of 0.5 hours to 1.5 hours, the temperature of the
insulating device
increases from 10 F to 50 F in a duration of 22 hours to 28 hours, and the
temperature of
the insulating device increases from 0 F to 50 F in a duration of 24 hours to
30 hours.
[176] The ice retention was tested using the following test. More than 24
hours before the test,
the following steps are performed:
[177] Ensure test coolers are clean inside and out.
[178] Mark test coolers with unique identifier and record identifier and
description in test log or
notes.
[179] Using duct tape, place a thermocouple (T) in the approximate center of
the test cooler (C).
[180] The thermocouple tip should be approximately 1 inch above the cooler
floor. (See Fig. 11 for
an example of proper thermocouple set-up.)
[181] Condition test coolers by keeping test coolers inside (ambient
temperature 65-75 F) with
lids open for a minimum of 24 hours.
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[182] Calculate the amount of ice required for testing (to nearest 0.1 lbs.)
using the equation
below.
[183] Ice per cooler = 0.52 lbs. x Quart capacity of cooler
[184] Ice required = Ice per cooler x number of coolers
[185] Condition the ice by placing the ice in a freezer (-15 to -5 F) for a
minimum of 24 hours prior
to use.
[186] The day of the test, the following steps are performed:
[187] Gather Test Equipment
[188] Allow thermal chamber to reach a temperature of 100 F
[189] Scale ¨ place scale near freezer with test ice
[190] Data Logger ¨ ensure Data Logger has charged battery
[191] The test procedure is as follows:
[192] Bring test coolers to freezer with test ice.
[193] Place test cooler on scale and tare the scale.
[194] Break test ice with hammer.
[195] Using the scale as reference, quickly fill the test cooler with the
required amount of ice.
[196] Ensure that the ice is evenly distributed throughout the test cooler.
[197] Ensure that the connector end of the thermocouple is outside of the test
cooler and close
and secure the cooler lid.
[198] Repeat steps for the remaining test coolers.
[199] Arrange the coolers in the test area such that they all have even
amounts of direct sunlight
and airflow (one cooler does not block the other).
[200] Connect all thermocouples to the data logger.
[201] Check all thermocouple readings to ensure that all connections are
complete and the
channels are recording properly. (Note: The starting temperature inside each
test cooler
should be < 10 F).
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[202] Power up the data logger and configure to record with temperatures
recorded at less than
minute intervals.
[203] Begin recording and note time in test log.
[204] Allow the test to continue until the inside temperature of each test
cooler is 50 F.
[205] Stop recording.
[206] Disconnect thermocouples from data logger.
[207] Receive data from data logger.
[208] Remove test coolers from test area.
[209] Empty test coolers and allow them to dry.
[210] Remove thermocouples from test coolers
[211] Two samples were tested according to the above procedure. The results of
which are
reflected below.
Time from Time from Time from
0 F to 10 F 0 F to 50 F 10 F to 50 F
Time (mins.)
Days Hrs Min Days Hrs
Min
53
Test #1 1 3 53 1 3
0
49
Test #2 1 3 37 1 2
48
[212] Figs. 35A-366 show various views of another exemplary insulating device
5010. The example
insulating device 5010 is similar to the example discussed above in relation
to Figs. 24-30.
Like reference numerals refer to the same or similar elements of similar
functionality in all of
the various views; and, therefore, these elements are not described in detail.
However, in
this example the exemplary insulating device 5010 can be formed of a smaller
size, can
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include a top handle 5216, and may include an optional reinforcement sheet or
panel.
Nevertheless, it is contemplated that the insulating device examples discussed
herein could
include a similar top handle and reinforcement sheet or panel.
[213] Figs. 36A and 366 show a partial view of an example lid assembly 5300.
Fig. 35A shows a
partial cross-section view of the example lid assembly 5300. The example lid
assembly 5300
is similar to the examples above, however, can additionally include a
reinforcement sheet or
panel 5217 in the lid assembly 5300. Fig. 366 shows a partial top view of the
example lid
assembly to illustrate the reinforcement sheet 5217. The reinforcement sheet
or panel 5217
is configured to assist in preventing bowing of the handle 5216 and the lid
assembly 5300.
The reinforcement sheet or panel 5217 can be a relatively rigid sheet of
material in
comparison to the outer liner 5501, insulating layer 5502, and the inner layer
5500. In one
particular example, the reinforcement sheet or panel 5217 can be formed of a
suitable
polymer or plastic, such as polyethylene. However, any stiffener material that
is flexible
could be used and other examples, may include a thermoformed PE, a TPU
injection molded
custom component.
[214] In certain examples, the reinforcement sheet or panel 5217 can be flat,
corrugated or may
have a honey comb configuration. The panel 5217, however, can include other
patterns so
as to assist in preventing bowing of the handle 5216. In certain examples, the
reinforcement
sheet or panel can be 1 to 3 mm thick. The reinforcement sheet may include a
cover, which
can in certain examples, can be configured to prevent water from penetrating
the cover. In
other examples, additional fabric may be included to reinforce the handle.
[215] A reinforcement area or patch 5320 can be included on the lid assembly
5300 for supporting
the handle 5216. In certain examples, the patch 5320 can be welded to the lid
assembly
5300. However, the patch 5320 may also be omitted entirely. The handle 5216
may be
sewn to the lid assembly 5300 and the reinforcement panel 5217 by way of
thread 5219.
The handle 5216 may also extend through the lid assembly and be directed
connected to the
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reinforcement panel 5217. In addition, instead of using a thread, the handle
5216 can be
connected to the reinforcement sheet or panel 5217 by one or more welds, bolts
or other
threaded-like connection, bayonet, ball and socket, and the like. Other
connection methods
may include providing either layers 5501A1 or 5501A2 with one or more slots
and the
reinforcement sheet or panel 5217 with one or more corresponding projections
that can be
located within the one or more slots, which allow for a more advanced
connection of the
sheet or panel 5217 to the lid assembly 5300 of the insulating device 5010.
Also a wireframe
or steel wire can be placed within the handle 5216 and extend through the
handle 5216.
The wireframe or steel wire can be threaded through the sheet or panel 5217 to
secure the
handle to the lid assembly 5300. It is also contemplated that all or portions
of the lid
assembly and/or handle can be injection molded to provide a more rigid
structure to
prevent bowing of the handle.
[216] The connection between the handle 5216 and the reinforcement panel 5217
also helps
prevent separation issues between the separate layers 5501A1, 5501A2, which
can be a TPU
coated nylon laminate, and a compression molded EVA material respectively. In
this
example, the connection between the handle and the reinforcement panel may
allow water
into the lid. However, at the same time, the connection can allow for any
liquid therein to
escape by evaporating through the opening formed by the connection. However,
it is also
contemplated that the connection between the handle and the reinforcement
panel may
also be waterproof or water resistant to limit the amount of moisture into the
lid assembly.
[217] Also the handle 5216 can be formed of a 1000D Nylon or other suitable
polymer and may
include 50mm webbing. Additionally, the handle 5216 may include padding on the
gripping
portion of the handle. In one example, the padding may be a suitable foam,
such as a 5 mm
polyethylene sponge foam. It is contemplated that the seal between the lid
assembly 5300
and the body assembly 5350 can be configured to withstand shock loading by the
handle
when the insulating device 5010 is sealed and filled with contents.
Nevertheless, a side
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bridge linking the lid assembly 5300 to the body assembly 5350 is also
contemplated for
transporting heavy items in the insulating device 5010.
[218] Figs. 37-416 illustrate another embodiment of insulating device 6010.
The example
insulating device 6010 can be of a similar construction to the above examples,
where like
reference numerals represent like features having similar functionality to
reference numeral
3XXX and 5XXX. These features having like reference numerals 6XXX may have
limited or no
description at all, but their functionality remains the same as their
corresponding 3XXX and
5XXX numerals. In this example, as can be seen in Figs. 37-416, the closure
6311 and
opening 6512 may be formed through a first sidewall 6507A, a second sidewall
670513, and a
third sidewall 6507C and partially through a fourth sidewall 6507D of the
insulating device
6010. Moreover, the opening 6512 is configured to provide access to the inner
chamber
6504 as is shown in Figs. 40A-416. Like in the above examples, the closure
6311 can be
substantially waterproof so as to resist liquid from exiting the opening 6512
when the
insulating device 6010 is in any orientation.
[219] As discussed above, the insulating device 6010 may include one or
more handles 6210,
6212, rings 6214, and webbing loops 6224 for attaching various items, e.g.
straps (shoulder),
carabineers, dry bags, keys, storage cases, etc. The rings 6214 can be D-
rings, and a
shoulder strap (not shown) can be connected to the D-rings for easy carrying
of the
insulating device. Also the rings 6214 can be attached to the insulating
device 6010 at
attachment points 6312, which can form loops or straps 6315a that also form a
slot for
receiving the rings 6214. For example, the straps 6315a, 6315b each form a
single loop on
the second and third sidewalls 650713, 6507C respectively. The straps 6315a,
6315b may be
only connected to their respective sidewalls 650713, 6507C on one side of the
loop formed to
receive the rings 6214. For example, as shown in Figs. 37-39, the strap 6315a
is connected
to the sidewall 6507C below the loop formed to receive the ring 6214.
Alternatively, the
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straps 6315a, 6315b may be connected to their respective sidewalls 650713,
6507C above the
loop formed to receive the respective ring 6214.
[220] Likewise, similar to the above examples, the outer shell 6501 can also
include multiple
reinforcement areas or patches 6320 that are configured to assist in
structurally supporting
the optional handles, straps, and webbing loops (e.g. 6210, 6212, 6213, 6214,
and 6224).
The handles or straps (e.g. 6210, 6212, 6213, 6214, and 6224) and other
attachments can be
stitched to the patches using threads 6222. In certain examples, these threads
6222 do not
extend through the outer shell 6501 into the insulating layer 6502. The
optional handles or
straps can be sewn to the patches 6320, and the patches 6320 can be RE welded
to the
outer shell 6501. Also, in other examples, the patches 6320 can be sewn or
adhered to the
outer shell 6501. Apertures from the stitching operation can provide venting
to the interior
defined by the outer shell 6501 and the inner liner 6500 of the insulating
device 6010. In
addition, other techniques are contemplated for securing the handles or straps
to the
insulating device 6010.
[221] Optionally or in addition to the venting configurations described
above with respect to the
configurations of insulating devices 3010 and 5010, insulating device 6010 may
have a
plurality of venting holes 6325 extending through the outer shell 6501. The
exploded view
of Fig. 39 shows the plurality of venting holes 6325 positioned underneath
patches 6320 and
further underneath and optional handles or straps 6210, 6212. The plurality of
venting holes
6325 may comprise any number of holes, such as the three holes 6325 shown in
Fig. 39.
Optionally, the plurality of holes 6325 may comprise two holes, four holes, or
greater than
four holes. The plurality of holes 6325 may be formed in a linear pattern to
be positioned
under the patches 6320 such as to not be visible from the exterior of the
insulating device
6010. Additionally, the plurality of holes 6325 may have a diameter of
approximately 3 mm,
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or within a range of 2 mm and 4 mm. The venting holes 6325 may help vent gases
that
become trapped between the inner liner 6500 and the outer shell 6501.
[222] Figs. 40A and 4013 illustrate an alternate embodiment of the insulating
layer 6502 of
insulating device 6010. The insulating layer 6502 may comprise a lower
insulating layer
portion 650213 may include a first sheet of insulating material 6 and a second
sheet of
insulating material 650262. Similar to the above examples, the first sheet of
insulating
material 6502131 and the second sheet of insulating material 650262 can be
free floating
layers of insulating material that are not attached to either the lower inner
liner portion
650013 or the lower outer shell portion 650113. However, it is also
contemplated that the first
sheet of insulating material 6502131 and the second sheet of insulating
material 650262 can
be attached to either the lower inner liner portion 650013 or the lower outer
shell portion
650113. Moreover, it is also contemplated that the lower insulating layer
portion 650213 be
formed of a single unitary piece.
[223] The upper insulating layer portion 6502A may be connected to the lid
assembly 6300
wherein the lid assembly includes at least a portion of the upper insulating
layer portion
6502A that extends beyond the closure 6311 adapted to close the opening 6512.
As the
upper insulating layer portion 6502A may extend beyond the closure 6311, a
portion of the
upper insulating layer portion 6502A and the upper inner liner portion 6500A
may contact
the lower inner liner portion 650013 and the lower insulating layer portion
650213 when the
closure 6311 is sealed to improve the insulation of the storage compartment
6504. For
example, the closure 6311 may force the upper inner liner portion 6500A to
contact the top
strip 6500131 of the lower inner liner portion 650013. Optionally or in
addition, a portion of
the upper insulating layer portion 6502A may be inwardly tapered to
accommodate and
provide space for the closure 6311. Further, the upper insulating layer
portion 6502A may
extend along the length of the closure 6311 to insulate the insulation
container 6010 along a
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length of the closure 6311. In addition, the upper insulating layer portion
6502A may
extend along the length of the hinge 6503 to insulate along the length of the
hinge 6503.
[224] The insulating layer 6502 may have multiple thicknesses. For example,
the upper insulating
layer portion 6502A may have a thickness that is greater than thickness of the
lower
insulating layer portion 650213 and/ or greater than a thickness of the
insulating layer
portions 6502131 and 650283. As shown in Fig. 40A, the upper insulating layer
portion 6502A
may have a constant thickness of approximately 51 mm or within a range of 38
mm to 64
mm, while the lower insulating layer portion 650282 and the insulating layer
portions
6502131, 650283 on the sidewalls 6507A, 670513, 6507C may have a constant
thickness of
approximately 38 mm or within a range of 25.4 mm to 51 mm. In addition, the
thickness of
the upper insulating layer portion 6502A may be expressed as a ratio of the
thickness of the
upper insulating layer portion 6502A to the thickness of the lower insulating
layer portion
650213 of at least one of the sidewalls 6507A, 670513, 6507C may be
approximately 1.3:1, or
within a range of 1.2:1 and 1.5:1. Alternatively, the thickness of the upper
insulating layer
portion 6502A may be expressed as a function of the ratio of the thickness of
the upper
insulating layer portion 6502A to the overall height of the insulating device
6010, where the
overall height 6513 defined as the vertical distance for the top of the lid
assembly 6300 to
the bottom of the body assembly 6350. For example, in the embodiment shown in
Fig. 40A,
the ratio of the thickness of the upper insulating layer portion 6502A to the
overall height
6513 of the insulating device 6010 may be approximately 6.5:1, or within a
range of 5.8:1 to
7.2:1. In addition, the thickness of the lower insulating layer portion 650213
on the sidewalls
6507A, 670513, 6507C may be expressed as a function of the overall width of
the insulating
device. For example, the overall width 6519 of the insulating device 6010
compared to a
thickness of the lower insulating layer portion 650213 connected to at least
one sidewall may
be approximately 11.5:1, or within the range of 10.3:1 to 12.7:1.
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[225] Figs. 41A and 416 shows another embodiment of where the upper insulating
layer portion
6502A connected to the lid assembly 6300 includes at least a portion of the
upper insulating
layer portion 6502A that extends beyond the closure 6311 adapted to close the
opening
6512. As shown in Figs. 41A and 416, the upper insulating layer portion 6502A
may
comprise a plurality of components. For example, the upper insulating layer
portion 6502A
may comprise a substantially uniform thickness insulating layer portion 6502D
nearer the
top of the lid assembly and an insulating ring 6502F around the perimeter
edges 6515 of the
upper insulating layer portion 6502A. The insulating ring 6502F may extend
underneath the
insulation sheet 6502D and have a shape that approximates the circumference of
the
insulation sheet 6502D. As the upper insulating layer portion 6502A may extend
beyond the
closure 6311, a portion of the insulating ring 6502F and the upper inner liner
portion 6500A
may contact the lower inner liner portion 650013 and the lower insulating
layer portion
650213 when the closure 6311 is sealed to improve the insulation of the
storage
compartment 6504. For example, the closure 6311 may force the upper inner
liner portion
6500A to contact the top strip 6500131 of the lower inner liner portion
650013. The upper
inner liner portion 6500A may follow the contour of the upper insulating layer
6502A to
form a headspace 6527 extending above the closure 6311. Further, the
insulating ring 6502F
of the upper insulating layer portion 6502A may extend along the length of the
closure 6311
to insulate the insulation container 6010 along a length of the closure 6311.
In addition, the
insulating ring 6502F of the upper insulating layer portion 6502A may extend
along the
length of the hinge 6503 to insulate along the length of the hinge 6503.
[226] Since the upper insulating layer portion 6502A may have multiple
thicknesses that may
include a first thickness around the perimeter edges 6515 and second thickness
at the center
portion 6517. The thickness of the insulating ring portion 6502F may be
greater than the
thickness of the uniform thickness insulating layer portion 6502D.
Additionally, the overall
thickness defined as the combined thicknesses of both the uniform thickness
insulating layer
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portion 6502D and the insulating ring portion 6502F at the perimeter edges
6515 of the
upper insulating layer portion 6502A is greater than the overall thickness of
the center
portion 6517 of the upper insulating layer portion 6502A. The thickness of the
overall
combined thickness at the perimeter edges 6515 may also be expressed as a
ratio of the
overall combined thickness at the perimeter edges 6515 to the thickness of the
center
portion of the upper insulating layer may be approximately 2.25:1, or within a
range of 2:1
to 2.5:1. Optionally or in addition, a portion of the upper insulating layer
portion 6502A may
be tapered on each side of the insulating ring portion 6502F to accommodate
and provide
space for the closure 6311 and space for the hinge 6503. Alternatively, the
upper insulating
layer portion 6502A may be formed with the insulating ring portion 6502F as a
single unitary
piece.
[227] FIG. 42 schematically depicts an aerogel insulating structure 7800, or
aerogel structure 7800,
according to one or more aspects described herein. This schematic depiction of
the aerogel
insulating structure 7800 may be used in figures throughout this disclosure.
Accordingly,
where used, the aerogel insulating structure 7800 may include one or more of
the
implementations described in relation to FIGS. 43-51, among others.
Additionally, it is
contemplated that, where used throughout these disclosures, an aerogel
insulating structure
7800 may represent a single, or multiple discrete aerogel insulating structure
7800, without
departing from the scope of these disclosures.
[228] In one example, the aerogel insulating structure 7800 may represent a
rigid or semi-rigid
structure that is configured to be positioned within or around another
structure, such as one
or more insulating devices, as described throughout these disclosures. While
the aerogel
insulating structure 7800 is schematically depicted in FIG. 42 as a simple
rectangular shape,
it is contemplated that the aerogel insulating structure 7800 may be
configured with any
three-dimensional geometry, without departing from the scope of these
disclosures. In one
example, the geometry of the aerogel insulating structure 7800 may be formed
by one or
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more molding, machining, and/or chemical processes, such that the aerogel
insulating
structure 7800 is shaped to fit within or around a specific structure, or
portion of a structure.
Further, the aerogel insulating structure 7800 may be deformable, and may be
configured to
deform in response to an applied pressure, and conform to another geometrical
feature,
such as a wall or a cavity of an insulating device within or onto which the
aerogel insulating
structure 7800 is configured to be positioned. In one example, the aerogel
insulating
structure 7800 may be manufactured as a material that is initially partially
or fully
deformable, and subsequently partially or fully hardens. As such, the aerogel
insulating
structure 7800 may be positioned by spraying or injecting onto or into another
geometrical
feature, and such that the aerogel insulating structure 7800 may subsequently
transition
from a deformable to a partially or fully rigid structure.
[229] It is contemplated that the aerogel insulating structure 7800 may be
coupled to another
surface (not depicted in FIG. 42). This other surface may be an internal
surface within a
cavity, or an external surface of another structure, such as an insulating
device (e.g. device
10). The coupling may be removable or non-removable, and use adhesives, an
interference
fitting, welding, stitching, and/or one or more fasteners, or combinations
thereof. It is
further contemplated that the aerogel insulating structure 7800 may be loosely
positioned
within another structure such that it is uncoupled from other surfaces.
[230] In another example, the aerogel insulating structure 7800 may be
overmolded within
another structure, or may be encapsulated within another structure by spin
welding parts of
the structure around the aerogel insulating structure 7800.
[231] FIG. 43 schematically depicts one implementation of the aerogel
insulating structure 7800,
according to one or more aspects described herein. In one example, the aerogel
insulating
structure includes an aerogel material 7802, which may otherwise be referred
to as aerogel
insulation 7802, aerogel foam 7802, or aerogel 7802. Advantageously, the
aerogel 7802 may
reduce an overall/combined thermal conductivity when used within a structure,
such as one
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or more of the insulating structures described throughout these disclosures.
Further, due to
lower densities, the aerogel 7802 may reduce the overall weight of a
structure, when
compared to structures that have equivalent thermal performance, but do not
use aerogels.
It is contemplated that any aerogel type (material type), having any physical
properties
(thermal conductivity, density, among others), and/or dimensional properties
(pore size,
length, width and thickness dimensions, among others) may be used, without
departing
from the scope of these disclosures. For example, the aerogel 7802 may include
a silica
aerogel, a carbon aerogel, a metal oxide aerogel, or an organic polymer
aerogel, or
combinations thereof, among others. In one example, the thermal conductivity
of the
aerogel 7802 may be, in some examples, 0.1 W/m=K or less, 0.03 W/m=K or less,
or 0.01
W/m=K or less, among others. However, it is contemplated that aerogel with any
thermal
conductivity may be used, without departing from the scope of these
disclosures.
[232] FIG. 44 schematically depicts one implementation of the aerogel 7802,
according to one or
more aspects described herein. In one example, the aerogel 7802 may include an
internal
structure 7806, which may be surrounded by an external shell 7804. The
external shell 7804
may include a barrier that partially or wholly seals the internal structure
7806 from an
external environment around the aerogel 7802. As such, the external shell 7804
may
include a material that is partially or wholly impermeable to air and/or
water. Further, the
external shell 7804 may be partially or fully deformable. It is contemplated
that the external
shell 7804 may include any a polymer, a fiber-reinforced material, a metal, an
alloy, or
combinations thereof. The internal structure 7806 of the aerogel 7802 may
include a
structural frame of the aerogel. This structural frame may be contiguous, or
may include
several separate portions. Additionally, the internal structure 7806 may
include an aerogel
powder, among others. In another example, the internal structure 7806 may
include aerogel
in combination with fiberglass
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[233] FIG. 45 schematically depicts another implementation of the aerogel
7802, according to one
or more aspects described herein. Accordingly, in one implementation, the
aerogel 7802
may be used within a vacuum-insulated panel structure 7808. In one example, an
aerogel
lattice may provide a bracing structure that retains the form of the vacuum-
insulated panel
structure 7808 under vacuum. In this regard, it is contemplated that any
vacuum-insulated
panel shell material and vacuum level may be used, without departing from the
scope of
these disclosures.
[234] FIG. 46 schematically depicts another implementation of the aerogel
7802, according to one
or more aspects described herein. Accordingly, in one example, the aerogel
7802 may
include multiple vacuum-insulated panel structures 7808a-7808c.
Further, it is
contemplated that any number of vacuum insulated panel structures may be used,
and in
any configuration within the aerogel 7802, without departing from the scope of
these
disclosures.
[235] FIG. 47 schematically depicts another implementation of the aerogel
7802, according to one
or more aspects described herein. In one example, the aerogel 7802 may be
configured to
be rolled, bent and/or folded around corners and/or curves of a structure onto
or into which
the aerogel 7802 is positioned. As such, a layer or panel of aerogel 7802 may
include
geometric features, such has skiving features 7810a-7810h that facilitate
bending and/or
folding of the aerogel 7802.
[236] FIG. 48 schematically depicts another implementation of the aerogel
insulating structure
7800, according to one or more aspects described herein. In one example, an
aerogel 7802
may be used in combination with another insulating layer 7810. As such, the
insulating layer
7810 may be similar to the insulating layer 502, and may include, among
others, an
insulating foam, such as a NBR/PVC blended foam, a PVC free NBR foam, or other
eco-
friendly type foam, or combinations thereof. It is contemplated that the
insulating layer
7810 may be coupled to the aerogel 7802 by one or more adhesives, by one or
more
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welding processes, by stitching, and/or one or more fasteners (rivets, screws,
staples, nails,
among others). In one implementation, the aerogel 7802 and the insulating
layer 7810 may
be coupled to one another during one or more processes used to manufacture the
aerogel
7802 and/or insulating layer 7810. In another example, the aerogel 7802, and
the insulating
layer 7810 may not be coupled to one another, and may be loosely positioned
proximate
one another.
[237] It is contemplated that the aerogel insulating structure 7800 may be
positioned within
another structure in any orientation. For example, the layer of aerogel 7802
may be
positioned within an insulating device (e.g. insulating device 10) such that
it is internally
oriented and the insulating layer 7810 is externally oriented. As such, the
aerogel 7802 may
be positioned closer to an internal storage compartment, such as receptacle
504, than the
insulating layer 7810. However, the orientation of the aerogel insulating
structure 7800 may
be reversed, without departing from the scope of these disclosures. It is also
contemplated
that the aerogel 7802 and/or insulating layer 7810 may have any thickness
values, without
departing from the scope of these disclosures.
[238] FIG. 49 schematically depicts another implementation of the aerogel
insulating structure
7800, according to one or more aspects described herein. In one example, a
layer of aerogel
7802 may be positioned between two insulating layers 7810a and 7810b. It is
further
contemplated that additional corresponding or alternating layers of aerogel
7802 and
insulating layer 7810 may be used, without departing from the scope of these
disclosures.
[239] FIG. 50 schematically depicts another implementation of the aerogel
insulating structure
7800, according to one or more aspects described herein. In one example, a
barrier
structure, or layer 7812 may be positioned between the aerogel 7802 and
insulating layer
7810. The barrier structure 7812 may facilitate improved adhesion of the
aerogel 7802
and/or insulating layer 7810 to one another, and/or serve to keep the aerogel
7802 and
insulating layer 7810 separate from one another. It is contemplated that the
barrier
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structure 7812 may be constructed from any polymer, metal, alloy, or fiber-
reinforced
material, or combinations thereof, without departing from the scope of these
disclosures.
[240] FIG. 51 schematically depicts another implementation of an aerogel
insulating structure
7800, according to one or more aspects described herein. Accordingly, the
aerogel
insulating structure 7800 may include multiple randomly spaced portions of
insulating layer
material 7810a-7810f and aerogel 7802a-7802f
[241] FIG. 52 depicts another implementation of an insulating device 7010,
according to one or
more aspects described herein. In one example, the insulating device 7010 may
be similar
to insulating device 3010 and/or insulating device 5010. It is contemplated
that like
reference numerals may refer to the same or similar elements that have similar
functionality. As such, a like reference numeral may have a same last three
digits as a
previously described element. In one specific example, the lid assembly 7300
of insulating
device 7010 may be similar to lid assembly 3300 and/or 5300, since all of
these elements
have the same last three digits (300). In another example, elements that have
the same last
three digits followed by a letter, or letter and number combination, may also
represent
similar elements that have similar functionality. For example, element 750082
may be
similar to element 550082. Accordingly, it is assumed that any previous
descriptions of
these similar elements having like reference numerals are applicable to
insulating device
7010 and lid assembly 7300, without need for repetition of the descriptions
here.
[242] FIG. 53 schematically depicts a cross-sectional view of the insulating
device 7010 along line
53-53 schematically depicted in FIG. 52. In one example, the insulating device
7010 may use
aerogel insulating structures 7800, as previously described. Additionally or
alternatively,
one or more aerogel insulating structures 7800 may be used within the lid
assembly 7300.
Further, the aerogel insulating structures 7800 may be used in combination
with insulating
layers 7502, 7502A, 7502131, 750282, which may be collectively referred to as
insulating
layers 7502. These insulating layer 7502 may include one or more insulating
foams, as have
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been previously described. The insulating layers 7502 and the aerogel
insulating structures
7800 may be bonded together using one or more adhesives. However, it is
contemplated
that any coupling type or methodology may be utilized, without departing from
the scope of
these disclosures. As such, it is contemplated that the insulating layers 7502
and aerogel
insulating structures 7800 may be referred to as a combined or contiguous unit
or structure.
[243] In one example, the insulating layer 7502 and/or the aerogel insulating
structure 7800 may
be loosely positioned between inner liner 7500 and the outer shell 7501. In
this way, the
insulating layer 7502 and/or the aerogel structure 7602 may be described as
floating
between the inner liner 7500 and the outer shell 7501. Alternatively, one or
more of the
insulating layer 7502 and/or the aerogel structure 7602 may be coupled to one
or more of
the inner liner 7500 and the outer shell 7501. Further, it is contemplated
that any adhesive
and/or coupling mechanism may be used, without parting from the scope of these
disclosures.
[244] In one implementation, and as schematically depicted in FIG. 53, the
aerogel insulating
structures 7800 may be used on internal sides (proximate the internal chamber
7504), and
one or more insulating layers 7502 may be used on external sides of the
insulating device
7010 and lid assembly 7300. It is contemplated, however, that the aerogel
insulating
structure 7800 may alternatively be used on the external sides, and the
insulating layers
7502 may be used on the internal sides of the insulating device 7010 and lid
assembly 7300,
without departing from the scope of these disclosures.
[245] It is further contemplated that one or more aerogel insulating structure
7800 structures may
be used with any of the insulating containers, structures, and/or devices
described
throughout this disclosure to provide, among others, enhanced thermal
properties and/or
weight reduction.
[246] In one example, the aerogel insulating structures 7800 may be rigid, or
may be partially or
fully deformable such that the aerogel insulating structures 7800 may be
configured to bend
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and flex without failure as one or more structures of the insulating device
7010 and/or lid
assembly 7300 are deformed.
[247] FIG. 54 schematically depicts a cross-sectional view of an alternative
implementation of an
insulating device 8010 and lid assembly 8300, according to one or more aspects
described
herein. The insulating device 8010 may be similar to the insulating device
7010, and the lid
assembly 8300 similar to the lid assembly 7300. However, the insulating device
8010 and
the lid assembly 8300 may use aerogel insulating structures 7800 without the
insulating
layers 7502 used in insulating device 7010, and lid assembly 7300.
[248] FIG. 55 schematically depicts another cross-sectional view of an
alternative implementation
of an insulating device 9010 and lid assembly 9300. In one example, the
insulating device
9010 and lid assembly 9300 may be similar to the insulating device 6010 and
lid assembly
6300, respectively. However, the insulating device 9010 and lid assembly 9300
may include
aerogel insulating structures 7800. As before, it is contemplated that like
reference
numerals may refer to the same or similar elements that have similar
functionality. A like
reference numeral may have a same last three digits as a previously described
element, or a
same last three digits followed by a letter, or letter and number combination.
Accordingly, it
is assumed that any previous descriptions of these similar elements having
like reference
numerals are applicable to insulating device 9010 and lid assembly 9300,
without need for
repetition of the descriptions here.
[249] Accordingly, the lid assembly 9300 may include an insulating ring
9502F and aerogel
insulating structure 7800F around one or more perimeter edges 9515 of the
upper insulating
layer portion 9502A and upper aerogel insulating structure 7800A. As the upper
insulating
layer portion 9502A may extend beyond the closure 9311, a portion of the
insulating ring
9502F and aerogel ring structure 9602F and the upper inner liner portion 9500A
may contact
the lower inner liner portion 950013 and the lower insulating layer portion
950213 when the
closure 9311 is sealed to improve the insulation of the storage compartment
9504.
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[250] As depicted in FIG. 55, the lid assembly 9300 and insulating device 9010
may include aerogel
insulating structures 7800 that are coupled to insulating layer portions 9502
(the insulating
layer portions 9502 labels in FIG. 55 may include additional letters and
numbers to identify
specific locations of the same or similar insulating materials within the
insulating device
9010 and/or lid assembly 9300, e.g. 9502A, 950213, 9502131, 950282, 9502F,
9502D). As
previously described, the aerogel insulating structures 7800 may be coupled to
the
insulating layer portions 9502 by one or more adhesives and/or fasteners. In
another
example, one or more of the aerogel insulating structures 7800 may be loosely
positioned
proximate one or more of the insulating layer portions 9502.
[251] FIG. 56 schematically depicts a cross-sectional view of an insulating
device 10010, and lid
assembly 10300, according to one or more aspects described herein. In one
example, the
insulating device 10010 may be similar to insulating device 6010, and the lid
assembly 10300
may be similar to lid assembly 6300. Though, the insulating device 10010 and
lid assembly
10300 may include aerogel insulating structures 7800. However, the previous
descriptions
of the elements of insulating device 6010 and the lid assembly 6300 may be
applicable to
those elements of insulating device 10010 and lid assembly 10300 with similar
reference
numerals.
[252] FIG. 57 schematically depicts a cross-sectional view of an insulating
device 11010, according
to one or more aspects described herein. In one example, the insulating device
11010 may
be similar to insulating device 10. Though, the insulating device 11010 may
include aerogel
insulating structures 7800. However, the previous descriptions of the elements
of insulating
device 10 may be applicable to those elements of insulating device 11010 with
similar
reference numerals.
[253] FIG. 58 schematically depicts a cross-sectional view of an insulating
device 12010, according
to one or more aspects described herein. In one example, the insulating device
12010 may
be similar to insulating device 4010, as described in relation to FIG. 21.
Though, the
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insulating device 12010 may include aerogel insulating structures 7800.
However, the
previous descriptions of the elements of insulating device 4010 may be
applicable to those
elements of insulating device 12010 with similar reference numerals.
[254] FIG. 59 schematically depicts an isometric view of an insulating
container 13001 and lid
structure 13003, according to one or more aspects described herein. In one
example, the
insulating container 13001 may have a substantially cuboidal shape, and may be
constructed
from one or more polymers, metals, alloys, fiber-reinforced materials, or
combinations
thereof. In one implementation, the lid structure 13003 may be hingedly-
coupled to the
insulating container 13001. For example, the lid structure 13003 may be
hingedly-coupled
to the insulating container 13001 along a first edge 13005 of a top portion
13007 of the
insulating container 13001.
[255] In one implementation, the insulating container 13001 and lid structure
13003 may
comprise double wall construction. As such, one or more cavities formed within
the
insulating container 13001 and lid structure 13003 may be partially or wholly
filled with an
insulating material. This insulating material may include one or more
polymeric materials
(e.g. a foam, a lattice, a substantially solid structure, and the like),
and/or an aerogel
structure, such as aerogel insulating structure 7800, which is schematically
depicted inside
the double wall construction of the lid structure 13003. Additionally or
alternatively, the
insulating container 13001 and/or lid structure 13003 may include vacuum-
insulated double
wall structures. As such, the aerogel insulating structure 7800 may be used as
a standoff
structure to prevent the sidewalls of the lid structure 13003 from deforming
as a result of a
vacuum within the double wall construction of the lid structure 13003. In
another example,
the insulating container 13001 and/or lid structure 13003 may include one or
more vacuum-
insulated panel structures.
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[256] FIG. 60 schematically depicts an exploded isometric view of the
insulating container 13001,
according to one or more aspects described herein. In one example, a cavity
may be formed
between an inner structure 13009 and an outer shell 13011 of the insulating
container
13001. This cavity may be partially or wholly filled with an insulating
material, such as a
foam, an aerogel, or a vacuum insulated panel, or combinations thereof.
Additionally or
alternatively, the cavity between the inner structure 13009 and an outer shell
13011 may
contain a vacuum.
[257] In one example, in order to reduce or prevent deformation of one or more
sidewalls of the
inner structure 13009 and outer shell 13011, aerogel insulating structures
7800 may be
coupled to one or more surfaces of the insulating container 13001 (e.g.
surface 13013 of the
inner structure 13009, as schematically depicted in FIG. 60). These aerogel
insulating
structures 7800 may be used to maintain a separation distance between the
inner structure
13009 and outer shell 13011 in order to reduce or prevent deformation of the
sidewalls of
the insulating container 13001 as a result of a vacuum being formed within the
cavity
between the inner structure 13009 and outer shell 13011. Two aerogel
insulating structure
7800 are schematically depicted in FIG. 60, however, a single aerogel
insulating structure
7800, or three or more aerogel insulating structures 7800 may be used as
standoffs within
the insulating container 13001 and/or lid structure 13003, without departing
from the scope
of these disclosures.
[258] Further details of the double wall construction of the insulating
container 13001 and lid
structure 13003 are described in application PCT/US2017/016542, "Container and
Method
of Forming a Container, filed 3 Feb 2017, the entire contents of which are
incorporated
herein by reference for any and all non-limiting purposes.
[259] FIG. 61 schematically depicts a cross-sectional view of an insulating
device 13021, according
to one or more aspects described herein. The insulating device 13021 may be a
bottle that
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is used to store a volume of liquid, and have an insulated container 13023
that is removably
coupled to a lid or closure 13025. A cavity 13027 may be formed between a
first inner wall
13029 and a second outer wall 13031 of the insulated container 13023. This
cavity 13027
may contain a sealed vacuum. It is contemplated that the pressure of these
vacuum may
have any value, without departing from the scope of these disclosures.
Additionally or
alternatively, the cavity 13027 may be partially or wholly filled with one or
more insulating
materials, such as one or more foams, or an aerogel structure. In one example,
and as
schematically depicted in FIG. 61, the cavity 13027 may include an aerogel
insulating
structure 7800. Accordingly, it is contemplated that the aerogel insulating
structure 7800
within the cavity 13027 may be coupled to one or more of the first inner wall
13029 and
second outer wall 13031 before the inner wall 13029 and second outer wall
13031 are
coupled to one another by one or more processes. These coupling processes may
include
welding, brazing, tacking, folding, molding, or using one or more fasteners,
or combinations
thereof.
[260] The lid 13025 may also include an aerogel insulating structure 7800.
This aerogel insulating
structure 7800 within the lid 13025 may be overmolded with one or more
polymers, metals
and/or alloys. Additionally or alternatively, separate portions of the lid
13025 may be
welded together (e.g. by spin welding) to encapsulate the aerogel insulating
structure 7800.
[261] Further details of the insulating device 13021 are provided in U.S.
Application No.
15/197,180, titled "Containers and Lids and Methods of Forming Containers and
Lids," filed
29 June 2016, the entire contents of which are incorporated herein by
reference for any and
all non-limiting purposes.
[262] FIG. 62 depicts a cross-sectional view of a lid structure 13033,
according to one or more
aspects described herein. The lid structure 13033 may be similar to those lids
described in
International Application No. PCT/U516/47043, "Container with Magnetic Cap,"
filed 15 Aug.
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2016, the entire contents of which are incorporated herein by reference for
any and all non-
limiting purposes.
[263] The lid structure 13033 may include a spout opening 13035 and an outer
shell 13037 that
encapsulates, in one example, an aerogel insulating structure 7800. The
aerogel insulating
structure 7800 may be positioned within a cavity of the outer shell 13037
prior to one or
more welding processes that rigidly couple separate portions of the outer
shell 13037
together. In another example, the outer shell 13037 may be overmolded over the
aerogel
insulating structure 7800. In yet another example, the aerogel insulating
structure 7800 may
be injected into a cavity in the outer shell 13037 of the lid structure 13033.
[264] FIG. 63 depicts a deformable insulator 13041, according to one or more
aspects described
herein. In one example, the deformable insulator 13041 may be configured to
extend
around at least a portion of a container 13043 (e.g. an aluminum beverage can,
among
others). In one example, the deformable insulator 13041 may bend, fold and/or
compress
without structural failure. In another example, the deformable insulator 13041
may have a
partially rigid structure. In one implementation, the deformable insulator
13041 may be
constructed from an aerogel insulating structure 7800, as schematically
depicted in FIG. 63.
In one example, an outer surface 13045 of the deformable insulator 13041 may
be formed
by an outer surface of the aerogel insulating structure 7800. In another
implementation, the
outer surface 13045 may be an outer skin/ layer of material (e.g. a deformable
layer of
polymer) that retains the aerogel insulating structure 7800. A similar inner
surface (not
depicted) may be used inside the deformable insulator 13041, and this inner
surface may be
configured to contact the container 13043.
[265] FIG. 64 depicts an insulating container 13051, according to one or more
aspects described
herein. In one example, the insulating container 13051 includes a base portion
13053 that
may be similar to container 13001, and a lid portion 13055 that may be similar
to lid
structure 13003. Loosely, removably, or rigidly positioned on top of the
insulating container
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13051 is a cushion structure 13057. In one example, the cushion may include
one or more
layers of compressible material configured to deform and provide cushioning to
a user when
seated on the insulating container 13051. In one example, the one or more
layers of
compressible material may include an aerogel insulating structure 7800, as
schematically
depicted in FIG. 64. In one implementation, the aerogel insulating structure
7800 may be
encapsulated within the cushion structure 13057 by an outer skin or layer or
material. In
another example, the outer surfaces of the cushion structure 13057 may include
at least a
portion of the aerogel insulating structure 7800. It is further contemplated
that a similar
structure, including one or more partially or wholly deformable aerogel
insulating structures
7800, may be used in alternative elements, such as blankets, or items of
apparel, among
others.
[266] FIG. 65 schematically depicts a cross-sectional view of another
implementation of an
insulating container 13061, according to one or more aspects described herein.
In one
example, the insulating container 13061 may be a tumbler configured to store a
volume of
liquid within an internal reservoir 13063. The container 13061 may have an
opening 13071
that extends into the internal reservoir 13063. The container 13061 may
include a first inner
wall 13065 and a second outer wall 13067. A sealed cavity 13069 may be formed
between
the first inner wall 13065 and the second outer wall 13067. Accordingly,
container 13061
may be an insulated double-wall structure. In one example, a vacuum may be
formed within
the sealed cavity 13069. It is contemplated that this vacuum may be at any
pressure level,
without departing from the scope of these disclosures. In another example, one
or more
insulating materials may be positioned within the cavity 13069, such as one or
more aerogel
insulating structures 7800.
[267] Further details of insulating containers similar to container 13061
are found in U.S.
Application No. 15/285,268, titled "Container and Method of Forming a
Container," filed 4
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Oct. 2016, the entire contents of which are incorporated herein by reference
for any and all
non-limiting purposes.
[268] An exemplary insulating device may include an outer shell, an inner
liner, an insulating layer
floating freely in between the outer shell and the inner liner, and a
waterproof closure. The
top of the shell has first perimeter circumference, and the bottom of the
shell has a second
perimeter circumference. The first perimeter circumference can be equal to the
second
perimeter circumference. The closure can be a zipper assembly comprising a
plurality of
zipper teeth, and the zipper teeth can be formed of plastic or metal. The
outer shell can be
made of a double laminated TPU nylon fabric. The inner liner can be made of a
double
laminated TPU nylon fabric. The insulating layer can be formed of a closed
cell foam. The
insulating layer can be made of a NBR and a PVC blend, and at least a portion
of the
insulating layer can be constructed with an EVA foam layer. The outer shell
further can
include at least one of a strap or handle. The outer shell further can include
at least one ring
for securing the insulating device.
[269] An exemplary insulating device can include an outer shell, an inner
liner, a closure adapted
to seal at least one of the outer shell or the inner liner, and an insulating
layer between the
outer shell and the inner liner. The closure can have a first flange and a
second flange, and
the outer liner can be secured to top surfaces of the first flange and the
second flange and
the inner liner can be secured to bottom surfaces of the first flange and the
second flange.
The outer liner and the inner liner can be connected to the closure by a
polymer weld. The
outer shell can have a first circumference and a second circumference, the
first
circumference and the second circumference both having an oval shape. The
closure can be
adapted to be a barrier against fluid. The closure can be a zipper apparatus
that is
watertight up to 7 psi above atmospheric pressure.
[270] An exemplary method of assembling an insulating device may include
forming an inner liner
having an inner vessel, forming an outer shell, forming an insulating layer
between the inner
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liner and the outer shell, and securing a closure configured to be a barrier
against fluid
penetration in and out of the inner vessel wherein the closure is secured in a
flat plane and
is secured to the outer shell and the inner shell. The outer shell and inner
shell may only be
connected to the closure and not to the insulating layer between the outer
shell and inner
liner.
[271] A waterproof polymer weld can be formed between the closure and the
inner shell and the
closure and the outer shell when the closure, the outer shell, and the inner
liner are lying in
a horizontal plane. The outer shell and the inner layer can be formed of a TPU
nylon
material. The closure can have a first flange and a second flange. The outer
liner can be
secured to top surfaces of the first flange and the second flange and the
inner liner can be
secured to bottom surfaces of the first flange and the second flange.
[272] The method can also include forming the insulating layer from a
rectangular shape, and
rolling the rectangular shape into a cylindrical shape. The top of the
insulating layer has a
first perimeter circumference and the bottom of the insulating layer has a
second perimeter
circumference. The first perimeter circumference can be equal to the second
perimeter
circumference.
[273] Another example insulating device can include an outer shell, an inner
liner forming a
storage compartment, a foam layer floating freely in between the outer and
inner liner, the
foam layer providing insulation, an opening extending through the outer layer
and the inner
layer, and a closure adapted to substantially seal the opening. The closure
can be
substantially waterproof so as to resist liquid from exiting the opening.
[274] The insulating device can also include an upper wall and a base, the
upper wall defining an
upper wall circumference, an upper wall length and an upper wall width, and
the base
defining a base circumference, a base length and a base width. The upper wall
circumference can be equal to the base circumference and the ratio of the
upper wall length
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to the upper wall width can be greater than the ratio of the base length to
the base width. In
one example, a heat gain rate of the insulating device can be approximately
1.0-1.5 degF/hr.
[275] Another example method of forming an insulating device may include
forming an inner liner
first portion and an outer shell first portion, securing the inner liner first
portion and the
outer shell first portion to a sealable closure to form a cap assembly,
forming an inner liner
second portion and securing the inner liner second portion to the inner liner
first portion to
form an inner liner, forming an outer shell second portion, rolling a
rectangular foam portion
to form a first cylindrical foam portion and securing a foam base portion to
the first
cylindrical portion to form a foam assembly, inserting the foam assembly into
the outer shell
second portion, inserting the inner liner into the foam assembly, and
stitching the outer shell
first portion to the outer shell second portion. The inner liner first portion
and the outer
shell first portion can be welded to the closure. The closure can be provided
with at least
one flange and the flange can be secured to a bottom surface of the outer
shell first portion
and a top surface of the inner liner first portion. The foam can float between
the outer shell
second portion and the inner liner second portion.
[276] An example portable insulating device may include an outer liner, an
inner liner forming a
storage compartment, a foam layer in between the outer and inner liner. The
foam layer
can be adapted to provide insulation. The example portable insulating device
may also
include an opening extending through one of the outer layer and the inner
layer and a
closing means for substantially sealing the opening. The closure can be
substantially
waterproof.
[277] In one example, a portable cooler may include an aperture on the top of
the cooler that is
opened and closed by a zipper apparatus which allows access to a chamber
within the
cooler. The aperture prevents any fluid leakage out of the cooler if the
cooler is overturned
or in any configuration other than upright. The zipper assembly also prevents
any fluid from
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permeating into the cooler chamber if the cooler is exposed to precipitation,
other fluid, or
submersed under water.
[278] An example method of assembling a zipper apparatus and aperture
configured to be
impervious to water or other liquids and fluids can include attachment of a
waterproof
zipper via material welding to both an outer shell and an inner liner. This
method may result
in a chamber impervious to water and other liquids when the zipper apparatus
on the
aperture is sealed.
[279] In one example, an insulating device may include an outer shell, an
inner liner forming a
storage compartment, a foam layer floating formed in between the outer and
inner liner,
the foam layer providing insulation, an opening extending through the outer
layer and the
inner layer, a closure adapted to substantially seal the opening, the closure
being
substantially waterproof so as to resist liquid from exiting the opening when
the insulating
device is in any orientation. In one example, the top portion of the outer
shell can have a
first perimeter circumference in a first configuration. The outer shell may
include a bottom
portion, the bottom portion of the outer shell can have a second perimeter
circumference in
a second configuration that is different from the first configuration, and the
first perimeter
circumference can be equal to the second perimeter circumference. The first
configuration
and the second configuration can be both oval shaped. In one example, the
insulating
device may include an upper wall and a base, the upper wall can define an
upper wall
circumference, an upper wall length and an upper wall width, and the base can
define a base
circumference, a base length and a base width. The upper wall circumference
can be equal
to the base circumference and the ratio of the upper wall length to the upper
wall width can
be greater than the ratio of the base length to the base width. The cold
retention time of
the insulating device can be approximately 11 to 43 hours or more. However, in
one
example the cold retention time can be 11 to 15 hours. In another example the
cold
retention time can be approximately 12.24 hours. The heat gain rate of the
insulating device
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can be approximately 1 to 1.5 degF/hr, and, in one particular example, the
heat gain rate can
be approximately 1.4 degF/hr. The storage compartment can be configured to
maintain a
liquid therein while inverted for greater than 15 minutes. In one particular
example, the
storage compartment can be configured to maintain the liquid for a period of
greater than
30 minutes therein when inverted and a half of a volume of the storage
compartment is
filled with the liquid.
[280] In one example, the insulating layer can be floating freely in between
the outer shell and the
inner liner. The insulating layer can be formed of closed cell foam, and the
insulating layer
can be made of a NBR and a PVC blend. In one example least a portion of the
insulating
layer can be constructed with an EVA foam layer. The closure can be a zipper
assembly
comprising a plurality of zipper teeth, and the zipper teeth can be formed of
plastic.
[281] In one example, the outer shell and the inner liner can be made of a
double laminated TPU
nylon fabric. The outer shell further can include at least one of a strap or
handle. The outer
shell can include at least one ring for securing the insulating device. The
insulating layer can
be configured to maintain an internal temperature of the insulating device
below 50 degrees
Fahrenheit for 65 to 85 hours. The closure can be formed with a first flange
and a second
flange and the outer liner can be secured to top surfaces of the first flange
and the second
flange. The inner liner can be secured to bottom surfaces of the first flange
and the second
flange. The outer liner and the inner liner can be connected to the closure by
a polymer
weld. In one example, the closure can be watertight up to 2 to 14 psi above
atmospheric
pressure. A loop patch may also be provided on the insulating device.
[282] In another example, an insulating device may include an outer shell, an
inner liner forming a
storage compartment, a foam layer floating in between the outer and inner
liner, which
provides insulation, an opening extending through the outer layer and the
inner layer, a
closure adapted to substantially seal the opening. The closure can be
substantially
waterproof so as to prevent liquid from exiting the opening when the
insulating device is
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inverted for a period of greater than 15 minutes. The heat gain rate of the
insulating device
can be approximately 1.0 to 1.5 degF/hr. The insulting device can include at
least one
handle. The at least one handle can be configured to support 100 lbs. to 300
lbs. of weight
for 1 to 10 minutes without showing signs of failure. In one example, the
insulating device
can be configured to withstand 35 lbs. to 100 lbs. of puncture force.
[283] An example method of forming an insulating device can include forming an
inner liner first
portion and an outer shell first portion, securing the inner liner first
portion and the outer
shell first portion to a sealable closure to form a cap assembly, forming an
inner liner second
portion and securing the inner liner second portion to the inner liner first
portion to form an
inner liner, forming an outer shell second portion, rolling a rectangular foam
portion to form
a first cylindrical foam portion and securing a foam base portion to the first
cylindrical foam
portion to form a foam assembly, inserting the foam assembly into the outer
shell second
portion, inserting the inner liner into the foam assembly, and securing the
outer shell first
portion to the outer shell second portion to form the outer shell. The method
may also
include securing a closure configured to be a barrier against fluid
penetration in and out of
the inner vessel and forming a waterproof polymer weld between the closure and
the inner
shell and the closure and the outer shell when the closure, the outer shell,
and the inner
liner are lying in a flat plane.
[284] In an example, the inner liner first portion and the outer shell first
portion can be secured to
the closure. The closure can be provided with at least one flange, and the
flange can be
secured to a bottom surface of the outer shell first portion and a top surface
of the inner
liner first portion. The foam can freely float between the outer shell second
portion and the
inner liner second portion. The outer shell and inner shell are only connected
to the closure
and not to the insulating layer between the outer shell and inner liner. The
outer shell can
be formed of a TPU nylon material, and the inner liner can be formed from a
TPU nylon
material. The closure can include a first flange and a second flange. The
outer liner can be
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secured to top surfaces of the first flange and the second flange, and the
inner liner can be
secured to bottom surfaces of the first flange and the second flange. The top
of the
insulating layer can have a first perimeter circumference. The bottom of the
insulating layer
can have a second perimeter circumference. The first perimeter circumference
can be equal
to the second perimeter circumference.
[285] In one example, an insulating device can include an outer shell defining
a sidewall, an inner
liner forming a storage compartment, an insulating layer positioned in between
the outer
shell and the inner liner, the insulating layer providing insulation for the
storage
compartment, an opening extending through the outer shell and the inner liner,
and a
closure adapted to substantially seal the opening, the closure being
substantially waterproof
so as to resist liquid from exiting the opening when the insulating device is
in any
orientation. The insulating device may include a vertically extending front
facing surface and
the closure can be located on the front facing surface. A cross section of the
insulating
device can approximate a pentagon in an extended position, and a cross section
of the
insulating device can approximate a trapezoid in an extended position. The
insulating device
may also include a base, and the insulating layer can insulate the base. The
base may also
include an additional insulating layer.
[286] The insulating device may also include a fold-down portion configured to
cover the closure.
The fold-down portion comprising a first section and a second section and
wherein the first
section is free of the insulation layer and the second section includes the
insulation layer.
The fold-down portion can be at least partially free of foam. The fold-down
portion can be
configured to be secured to the sidewall. The fold-down portion can include at
least one
hook and the sidewall can include at least one loop. The hook can be
configured to engage
the loop to secure the fold-down portion to the sidewall. The fold-down
portion can be
secured to the sidewall, and the fold-down portion may extend at least partly
in a
substantially horizontal direction. The fold-down portion may define a first
width, and the
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closure extends across at least 95% of the first width. The fold-down portion
may also
include a handle configured to be grasped by a user when the fold-down portion
is secured
to the sidewall.
[287] The insulating layer may include a foam material. The insulating layer
may include a first
portion and a second portion, and the second portion can be formed thicker
than the first
portion. The insulating layer can be at least partly formed in a shape of a T.
The insulating
layer can be at least partly formed of a first rectangle and a second
rectangle and the first
rectangle can have a larger area than the second rectangle. The first
rectangle can have a
first rectangle width and the second rectangle can have a second rectangle
perimeter. The
first rectangle width can approximates the second rectangle perimeter. The
second
rectangle can extend into the fold-down portion. The insulating layer can have
a first height
and a second height and the first height can be greater than the second
height. A majority of
the insulating layer can extend to the second height.
[288] A method of forming an insulating device may include forming an inner
liner defining a
storage compartment, forming an outer shell defining a sidewall, placing an
insulating layer
in between the outer shell and the inner liner, the insulating layer providing
insulation for
the storage compartment, placing an opening in the inner liner and the outer
shell, and
placing a closure between the inner liner and the outer shell. The closure can
be adapted to
substantially seal the opening, and the closure can be substantially
waterproof so as to resist
liquid from exiting the opening when the insulating device is in any
orientation. The method
may also include forming a fold-down portion configured to cover the closure,
providing the
fold-down portion with a first section and a second section. The first section
can be free of
the insulation layer and the second section can include the insulation layer.
The fold-down
portion can be at least partially free of foam. The fold-down portion can be
configured to
secure to the sidewall. The method may also include forming the insulating
layer at least
partly in the shape of a T, forming the insulating layer at least partly of a
first rectangle and a
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second rectangle, and forming the first rectangle of a larger area than the
second rectangle.
The method may also include extending the second rectangle into the fold-down
portion
and providing the insulating layer on a base and providing an additional
insulating layer
along the base.
[289] In another example, an insulating device can include an outer shell
defining a sidewall, an
inner liner forming a storage compartment, and an insulating layer positioned
in between
the outer shell and the inner liner. The insulating layer can provide
insulation for the
storage compartment. The insulating device can include an opening configured
to allow
access to the storage compartment and a closure adapted to substantially seal
the opening.
The insulating device can include a binding material, and the binding material
can be placed
over a joint between the inner liner and the outer shell. The binding material
can be
stitched onto the insulating device, and the stitching can create openings
into the outer shell
for venting air trapped between the insulating layer and the outer shell. The
binding
material can create at least one strap for holding the insulating device. The
binding material
can include a first folded portion attached to the outer shell and a second
folded portion,
and the second folded portion can form a strap.
[290] The insulation device can approximate a trapezoid from a front view and
can approximate a
conical shape from a side view. In one example, the insulating device
increases from 0 F to
50 F in a duration of 70 hours or greater when filled with 0.52 lbs. of ice
per each quart in
capacity of the insulating device.
[291] The closure can be substantially waterproof so as to resist liquid from
exiting the opening
when the insulating device is in any orientation. In one example, the
insulating device can
be configured to withstand being held inverted for 15 minutes without any
water escaping
or leaving the storage compartment. The closure can be configured to stay in
the opened
position when the closure is not sealed. The closure can be a zipper. In one
example, the
closure extends at least 80% of the length of the insulating device when
measured along the
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closure. The length of the closure can be longer than the length of the bottom
of the
insulating device, and the length of the closure is at least 5% longer than
the length of the
bottom of the insulating device. The insulating device can include a
vertically extending
front facing surface, and the closure can be located on the front facing
surface. A handle can
be located on a rear facing surface opposing the front facing surface.
[292] In the example insulating device, the insulating layer can comprise a
foam material. The
insulating layer can comprise a first portion and a second portion, and the
second portion
can be formed thicker than the first portion. The insulating layer can be at
least partly
formed of a first rectangle and a second rectangle, and the first rectangle
can have a larger
area than the second rectangle. The insulating layer can have a first height
and a second
height, and the first height can be greater than the second height. In one
example, a
majority of the insulating layer can extend to the second height. In addition,
or alternatively,
the front of the insulating layer can extend to the second height and the rear
of the
insulating layer extends to the first height. The insulating device can
include a base, and the
insulating layer can insulate the base. Also the base can include an
additional or separate
insulating layer. In one example, the insulating layer can cover 80% or more
of the inner
liner covering the storage compartment or the insulating layer can cover 90%
or more of the
inner liner covering the storage compartment.
[293] In another example, a method of forming an insulating device may include
forming an inner
liner the inner liner defining a storage compartment, forming an outer shell
defining a
sidewall, placing an insulating layer in between the outer shell and the inner
liner, the
insulating layer providing insulation for the storage compartment, placing an
opening in the
inner liner and the outer shell, placing a closure between the inner liner and
the outer shell,
the closure adapted to substantially seal the opening, the closure being
substantially
waterproof so as to resist liquid from exiting the opening when the insulating
device is in any
orientation. The method can also include forming the insulating layer at least
partly of a first
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rectangle and a second rectangle and forming the first rectangle of a larger
area than the
second rectangle. The method can also include providing the insulating layer
on a base and
providing an additional insulating layer along the base.
[294] An example insulating device can include an outer shell defining a first
sidewall; an inner
liner forming a storage compartment; an insulating layer positioned in between
the outer
shell and the inner liner, the insulating layer providing insulation for the
storage
compartment. The outer shell and the inner liner can define an opening, and
the opening
can be configured to allow access to the storage compartment. A closure can be
adapted to
substantially seal the opening, and the closure can be substantially
waterproof so as to resist
liquid from exiting the opening when the insulating device is in any
orientation. The outer
shell may include a second sidewall and a third sidewall, and the opening may
extend
through the first sidewall, the second sidewall, and the third sidewall. The
insulating device
can be in the shape of a cuboid. The inner liner and the outer shell can form
a joint, and the
joint can include a vent to gases that become trapped between the inner liner
and the outer
shell. The outer shell may include one or more handles, and a vent can be
formed adjacent
to a location of the one or more handles. The closure can be substantially
waterproof so as
to resist liquid from exiting the opening when the insulating device is
dropped from a
distance of six feet.
[295] The insulating device can also include a lid assembly and a body
assembly. The lid assembly
and the body assembly can together form the inner liner, the insulating layer,
and the outer
shell. The lid assembly can include at least a portion of the insulation
layer. The lid
assembly may also include a handle and a reinforcement layer that is more
rigid than the
inner liner, the insulating layer, and the outer shell.
[296] The outer shell may define a bottom wall extending in a first plane, and
the inner liner can
be secured to the outer shell in a second plane extending perpendicular to the
first plane.
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The liner may be formed of a first piece and a second piece and the first
piece is joined to
the second piece by way of a weld to define a seam and the seam may be covered
with a
seam tape. In one alternative example, the inner liner can be formed by way of
injection
molding. The closure can be a zipper and can be substantially waterproof. The
zipper can
include a pull, and the pull can be formed of a cloth, string, or rope. In
certain examples, the
temperature of the insulating device increases from 0 F to 10 F in a duration
of 0.5 hours to
1.5 hours, the temperature of the insulating device increases from 10 F to 50
F in a duration
of 22 hours to 28 hours, and the temperature of the insulating device
increases from 0 F to
50 F in a duration of 24 hours to 30 hours.
[297] An example method may include forming a body assembly by forming a lower
outer shell,
placing a lower insulating layer into the lower outer shell, and securing a
lower inner liner
portion to the lower outer shell; forming a lid assembly of an upper outer
shell, an upper
inner liner portion and an upper insulating layer therebetween; and joining
the lid assembly
to the body assembly by securing a closure between the lid assembly and the
body assembly
and by securing a binding material to the body assembly and the lid assembly.
The
insulating layer can float between the lower outer shell and the lower inner
liner portion.
The binding material can be formed of nylon, and the binding material can be
stitched to the
body assembly and the lid assembly. The lid assembly may also be welded to the
body
assembly. Additionally, the lid assembly may be formed with a handle and a
reinforcement
layer that is more rigid than the inner liner, the insulating layer, and the
outer shell. The
lower inner liner portion in certain examples can be formed by injection
molding.
[298] The lower inner liner portion can be secured to the lower outer shell
by a weld. The weld
can be formed by clamping the lower outer shell to the lower inner liner
portion with a top
U-shaped portion, a plate portion, and a bottom U-shaped portion and applying
a current
through the top U-shaped portion, the plate portion, and the bottom U-shaped
portion. The
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current can be applied through the top U-shaped portion, the plate portion,
and the bottom
U-shaped portion in a first direction to weld a first side and the current can
be applied in a
second direction to weld a second side.
[299] Aspects of the disclosure herein may relate to insulating devices having
an outer shell
defining a first sidewall, an inner liner forming a storage compartment, an
insulating layer
positioned in between the outer shell and the inner liner, where the
insulating layer
providing insulation for the storage compartment. The
insulating device may have an
opening configured to allow access to the storage compartment, and a lid
assembly and a
body assembly, where the lid assembly and the body assembly together form the
inner liner,
the insulating layer, and the outer shell. The lid assembly may include at
least a portion of
the insulating layer that extends below a closure adapted to close the
opening. The closure
may be adapted to substantially seal the opening, the closure being
substantially waterproof
so as to resist liquid from exiting the opening when the insulating device is
in any
orientation. The insulating layer connected to the lid assembly may include a
perimeter
edges and a center portion, where the insulating layer connected to the lid
assembly has an
overall first thickness near the perimeter edges and a second thickness near
the center
portion, wherein the first thickness is greater than the second thickness. The
ratio of the
first thickness to the second thickness may be in a range of 2:1 to 2.5:1.
Additionally, a ratio
of an overall height of the insulating device compared to a thickness of the
insulating layer
connected to the lid assembly of the insulating device may be within a range
of 5.8:1 to
7.2:1. The thickness of the insulating layer connected to the lid assembly may
be greater
than a thickness of the insulating layer on the first sidewall.
[300] Still other aspects of this disclosure may relate to an insulating
device having an outer shell
further comprises a second sidewall and a third sidewall and wherein the
opening extends
through the first sidewall, the second sidewall, and the third sidewall and
where the
insulating device is in a shape of a cuboid. The insulating device may further
include the
outer shell having one or more handles and where a plurality of venting holes
extend
through the outer shell underneath one or more handles. The plurality of
venting holes may
comprise three holes.
[301] Yet other aspects of this disclosure may relate to an insulating device
having a lid assembly
that includes at least a portion of the insulating layer that extends below a
closure adapted
to substantially seal the opening, and where the outer shell comprises one or
more handles
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and a plurality of venting holes extending through the outer shell positioned
underneath the
one or more handles. The lid assembly may further comprise an insulation sheet
and an
insulating ring, wherein the insulating ring extends underneath the insulation
sheet and
approximates a circumference of the insulation sheet. A portion of the
insulating layer on
the lid assembly and the inner liner may form a headspace extending above the
closure. The
portion of the insulating layer and the inner liner of the lid assembly are
contact with the
inner liner and a second portion of the insulating layer formed on the body
assembly to form
the storage compartment when the closure is sealed. The
insulating layer on the lid
assembly may extend along a length of the closure to insulate the storage
compartment
along the length of the closure. The outer shell may form a hinge and the
portion of the
insulating layer on the lid assembly may extend along a length of the hinge to
insulate the
storage compartment along the length of the hinge. In addition, the portion of
the
insulating layer may be tapered to accommodate for the closure.
[302] The present invention is disclosed above and in the accompanying
drawings with reference
to a variety of examples. The purpose served by the disclosure, however, is to
provide
examples of the various features and concepts related to the invention, not to
limit the
scope of the invention. One skilled in the relevant art will recognize that
numerous
variations and modifications may be made to the examples described above
without
departing from the scope of the present invention.
Exemplary Clauses
1. An insulating device comprising:
an outer shell defining a first sidewall;
an inner liner forming a storage compartment;
an insulating layer coupled to an aerogel structure, positioned in between the
outer
shell and the inner liner on an external side of the, the insulating layer and
aerogel structure
providing insulation for the storage compartment;
an opening configured to allow access to the storage compartment; and
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a closure adapted to substantially seal the opening, the closure being
substantially
waterproof so as to resist liquid from exiting the opening when the insulating
device is in any
orientation.
2. The insulating device of clause 1 wherein the outer shell further comprises
a second
sidewall and a third sidewall and wherein the opening extends through the
first sidewall,
the second sidewall, and the third sidewall.
3. The insulating device of clause 1 wherein the insulating device is in a
shape of a cuboid.
4. The insulating device of clause 1 wherein the inner liner and the outer
shell form a joint
and wherein the joint comprises a vent to gases.
5. The insulating device of clause 1 wherein the outer shell comprises one or
more handles
and wherein a vent is formed adjacent to a location of the one or more
handles.
6. The insulating device of clause 1 wherein the closure is substantially
waterproof so as to
resist liquid from exiting the opening when the insulating device is filled
completely with
water and is dropped from a distance of six feet.
7. The insulating device of clause 1 wherein the outer shell defines a bottom
wall
extending in a first plane and wherein the inner liner is secured to the outer
shell in a
second plane extending perpendicular to the first plane.
8. The insulating device of clause 1 wherein the inner liner is formed of a
first piece and a
second piece and wherein the first piece is joined to the second piece by way
of a weld
to define a seam and wherein the seam is covered with a seam tape.
9. The insulating device of clause 1 wherein the inner liner is formed by way
of injection
molding.
10. The insulating device of clause 1 wherein the closure is a zipper and is
substantially
waterproof and wherein the zipper comprises a pull, the pull being formed of a
cloth,
string, or rope.
11. The insulating device of clause 1 wherein the temperature of the
insulating device when
filled with ice of approximately 0.52 lbs. per quart capacity of the
insulating device
increases from 0 F to 10 F in a duration of 0.5 hours to 1.5 hours.
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12. The insulating device of clause 1 wherein the temperature of the
insulating device when
filled with ice of approximately 0.52 lbs. per quart capacity of the
insulating device
increases from 10 F to 50 F in a duration of 22 hours to 28 hours.
13. The insulating device of clause 1 wherein the temperature of the
insulating device when
filled with ice of approximately 0.52 lbs. per quart capacity of the
insulating device
increases from 0 F to 50 F in a duration of 24 hours to 30 hours.
14. The insulating device of clause 1 further comprising a lid assembly and a
body assembly.
15. The insulating device of clause 14 wherein the lid assembly and the body
assembly
together form the inner liner, the insulating layer, the aerogel structure,
and the outer
shell.
16. The insulating device of clause 14 wherein the lid assembly includes at
least a portion of
the insulation layer and the aerogel structure.
17. The insulating device of clause 14 wherein the lid assembly includes a
handle and a
reinforcement layer that is more rigid than the inner liner, the insulating
layer, the
aerogel structure, and the outer shell.
18. The insulating device of clause 1 wherein the insulating layer and aerogel
structure float
between the inner liner and the outer shell.
19. The insulating device of clause 1 wherein the insulating layer and aerogel
structure are
attached to the inner liner or the outer shell.
20. A method comprising:
forming a body assembly by forming a lower outer shell, placing a lower
insulating layer
and aerogel structure into the lower outer shell, and securing a lower inner
liner portion to
the lower outer shell;
forming a lid assembly of an upper outer shell, an upper inner liner portion
and an upper
insulating layer and aerogel structure therebetween; and
joining the lid assembly to the body assembly by securing a closure between
the lid
assembly and the body assembly and by securing a binding material to the body
assembly
and the lid assembly.
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21. The method of clause 20 wherein the insulating layer and aerogel structure
floats
between the lower outer shell and the lower inner liner portion.
22. The method of clause 20 wherein the binding material is nylon.
23. The method of clause 20 wherein the binding material is stitched to the
body assembly
and the lid assembly.
24. The method of clause 20 wherein the lid assembly is also welded to the
body assembly.
25. The method of clause 20 wherein the lower inner liner portion is formed by
injection
molding.
26. The method of clause 20 wherein the lower inner liner portion is secured
to the lower
outer shell by a weld.
27. The method of clause 26 wherein the weld is formed by clamping the lower
outer shell
to the lower inner liner portion with a top U-shaped portion, a plate portion,
and a
bottom U-shaped portion and applying a current through the top U-shaped
portion, the
plate portion, and the bottom U-shaped portion.
28. The method of clause 27 wherein the current is applied through the top U-
shaped
portion, the plate portion, and the bottom U-shaped portion in a first
direction to weld a
first side and the current is applied in a second direction to weld a second
side.
29. The method of clause 20 further comprising forming the lid assembly with a
handle and
a reinforcement layer that is more rigid than the inner liner, the insulating
layer, the
aerogel structure, and the outer shell.
30. The method of clause 20 further comprising attaching the insulating layer
and aerogel
structure to the inner liner or the outer shell.
31. An insulating device comprising:
an outer shell defining a first sidewall;
an inner liner forming a storage compartment;
an insulating layer and aerogel structure positioned in between the outer
shell and
the inner liner, the insulating layer and aerogel structure providing
insulation for the storage
compartment;
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an opening configured to allow access to the storage compartment;
a lid assembly and a body assembly, wherein the lid assembly and the body
assembly
together form the inner liner, the insulating layer, the aerogel structure,
and the outer shell;
wherein the lid assembly includes at least a portion of the insulating layer
and aerogel
structure that extends below a closure adapted to close the opening.
32. The insulating device of clause 31, wherein the portion of the insulating
layer and aerogel
structure and the inner liner of the lid assembly contacts a second portion of
the
insulating layer and aerogel structure and the inner liner formed on the body
assembly to
form the storage compartment when the closure is sealed.
33. The insulating device of clause 31, wherein the insulating layer and
aerogel structure
connected to the lid assembly comprises a perimeter edges and a center
portion, wherein
the insulating layer and aerogel structure connected to the lid assembly has
an overall first
thickness near the perimeter edges and a second thickness near the center
portion, wherein
the first thickness is greater than the second thickness.
34. The insulating device of clause 33, wherein a ratio of the first
thickness to the
second thickness is in a range of 2:1 to 2.5:1.
35. The insulating device of clause 33, wherein a ratio of an overall
height of the
insulating device compared to a thickness of the insulating layer and aerogel
structure
connected to the lid assembly of the insulating device is within a range of
5.8:1 to 7.2:1.
36. The insulating device of clause 31, wherein a thickness of the
insulating layer and
aerogel structure connected to the lid assembly is greater than a thickness of
the insulating
layer and aerogel structure on the first sidewall.
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37. The insulating device of clause 31, wherein the outer shell further
comprises a second
sidewall and a third sidewall and wherein the opening extends through the
first sidewall,
the second sidewall, and the third sidewall.
38. The insulating device of clause 31 wherein the insulating device is in a
shape of a cuboid.
39. The insulating device of clause 31, wherein the outer shell comprises one
or more
handles and wherein a plurality of venting holes extending through the outer
shell are
positioned underneath one or more handles.
40. An insulating device comprising:
an outer shell defining a first sidewall;
an inner liner forming a storage compartment;
an insulating layer and aerogel structure positioned in between the outer
shell and
the inner liner, the insulating layer and aerogel structure providing
insulation for the storage
compartment;
an opening configured to allow access to the storage compartment;
a lid assembly and a body assembly, wherein the lid assembly and the body
assembly
together form the inner liner, the insulating layer, the aerogel structure,
and the outer shell;
wherein the outer shell comprises one or more handles and wherein a plurality
of
venting holes extending through the outer shell are positioned underneath one
or more
handles.
41. The insulating device of clause 40, wherein the plurality of venting holes
comprises three
holes.
42. The insulating device of clause 40, wherein the insulating layer and
aerogel structure
connected to the lid assembly comprises a perimeter edges and a center
portion, wherein
the insulating layer and aerogel structure connected to the lid assembly has a
first
thickness near the perimeter edges and a second thickness near the center
portion,
wherein the first thickness is greater than the second thickness.
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43. The insulating device of clause 42, wherein a ratio of the first thickness
to the second
thickness is in a range of 2:1 to 2.5:1.
44. An insulating device comprising:
an outer shell defining a first sidewall;
an inner liner forming a storage compartment;
an insulating layer and aerogel structure positioned in between the outer
shell and
the inner liner, the insulating layer and aerogel structure providing
insulation for the storage
compartment;
an opening configured to allow access to the storage compartment;
a lid assembly and a body assembly, wherein the lid assembly and the body
assembly
together form the inner liner, the insulating layer, the aerogel structure and
the outer shell;
wherein the lid assembly includes at least a portion of the insulating layer
and aerogel
structure that extends below a closure adapted to substantially seal the
opening, and
wherein the outer shell comprises one or more handles and wherein a plurality
of
venting holes extending through the outer shell are positioned underneath one
or more
handles.
45. The insulating device of clause 44, wherein the lid assembly further
comprises an
insulation sheet and an insulating ring, wherein the insulating ring extends
underneath
the insulation sheet and approximates a circumference of the insulation sheet.
46. The insulating device of clause 44, wherein the portion of the insulating
layer and aerogel
structure on the lid assembly and the inner liner form a headspace extending
above the
closure.
47. The insulating device of clause 44, wherein the portion of the insulating
layer and aerogel
structure and the inner liner of the lid assembly contacts a second portion of
the
insulating layer and aerogel structure and the inner liner formed on the body
assembly to
form the storage compartment when the closure is sealed.
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48. The insulating device of clause 44, wherein the insulating layer and
aerogel structure
extends along a length of the closure to insulate the storage compartment
along the
length of the closure.
49. The insulating device of clause 48, wherein the outer shell forms a hinge
and the portion
of the insulating layer and aerogel structure on the lid assembly extends
along a length of
the hinge to insulate the storage compartment along the length of the hinge.
50. The insulating device of clause 48, wherein the portion of the insulating
layer and aerogel
structure is tapered to accommodate for the closure.
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